Roadway reflector

A roadway reflector comprising:

• a composite upper member being generally circular and including a retroreflective element, a metal disk and a polymeric covering;
• a plurality of tabs spaced on a perimeter of the disk;
• a composite base member being generally circular and adapted to be inserted into an opening in a roadway so that the base member is at least partially embedded in the roadway, the base member including a polymeric annular wall and a metal ring bonded to the annular wall;
• a plurality of notches on an interior edge of the ring, the notches being sized and configured to mate with the plurality of tabs on the disk so that rotational movement of the upper member relative to the base member couples them together so that the upper member projects above the roadway when the base member is inserted into the opening;
• an annular resilient member integrally formed with the annular wall of the base member and joining the metal ring with the annular wall so that when an item contacts the upper member the resilient member permits the upper member to deflect downwardly and at least partially into the base member and then rebound upwardly after the item passes the reflector;
• a first and second ramp projecting upwardly from the disk so that when the reflector is embedded in the roadway the item passing over the reflector contacts the ramps;
• wherein the reflector element is positioned between the first and second ramps and an upper surface of the reflector element is recessed relative to an upper surface of the ramps;
• a first and second spaced hummock on the disk with the reflector element positioned therebetween so that the item passing over the reflector initially contacts one of the hummocks prior to contacting the ramps;
• wherein the polymeric covering bonds the reflector element to the disk and substantially covers the disk and the hummocks with a reflective surface;
• an annular flange extending around a perimeter of the polymeric covering and at least partially overlying the resilient member, wherein the flange and the resilient member cooperate to inhibit foreign matter from entering the reflector and to expel foreign matter from the reflector when the upper member deflects downwardly into the base member;
• an expansion ring seated within the base member;
• an expansion joint on the expansion ring which upon actuation enlarges the expansion ring to force the annular wall of the base member against a sidewall of the opening in the roadway and frictionally retain the reflector in the opening;
• a plurality of serrations on the annular wall to enhance the frictional interaction between the base member and the sidewall of the opening;
• and
• a rounded upper edge on the expansion ring to minimize damage to the base member when the upper member deflects downwardly.

A method of making a reflector adapted to be embedded into an opening in a roadway, the method comprising:

• bonding a reflector element to a generally circular metal disk between a first and second ramp projecting upwardly from the disk so that the reflector element is recessed relative to an upper surface of the ramps, the disk having a plurality of connector elements spaced around a perimeter thereof;
• bonding a metal ring to a resilient web which is integrally formed with an annular wall, the ring having a plurality of mating connector elements;
• aligning the plurality of connector elements on the disk with the plurality of mating connector elements on the ring;
• and
• coupling the disk and the ring to each other by engaging the connector elements with the mating connector elements.

A reflector manufactured from a method comprising:

• bonding a reflector element to a generally circular metal disk between a first and second ramp projecting upwardly from the disk so that the reflector element is recessed relative to an upper surface of the ramps, the disk having a plurality of connector elements spaced around a perimeter thereof;
• bonding a metal ring to a resilient web which is integrally formed with an annular wall, the ring having a plurality of mating connector elements;
• aligning the plurality of connector elements on the disk with the plurality of mating connector elements on the ring;
• and
• coupling the disk and the ring to each other by engaging the connector elements with the mating connector elements.