# US 8,783,999 B2 · Water-ballasted protection barriers and methods

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- Number: US 8,783,999 B2
- Document ID: US8783999B2
- Status: Granted
- Kind: B2
- Application number: 13/948,093
- Filed: 2013-07-22
- Published: 2013-11-21
- Granted: 2014-07-22
- Earliest claimed: 2009-02-03
- Assignees: Traffix Devices, Inc.
- Applicants: Jack H. Kulp; Felipe Almanza; Geoffrey B. Maus; Paul Burlingham
- Inventors: Jack H. Kulp; Felipe Almanza; Geoffrey B. Maus; Paul Burlingham
- Web page: https://patentgrep.com/patent/US8783999B2

## CPC

- B29C 39/08: Introducing the material into the mould by centrifugal force
- E01F 15/086: {using plastic, rubber or synthetic materials}
- E01F 15/088: {Details of element connection}
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- E01F: ADDITIONAL WORK, SUCH AS EQUIPPING ROADS OR THE CONSTRUCTION OF PLATFORMS, HELICOPTER LANDING STAGES, SIGNS, SNOW FENCES, OR THE LIKE

## Abstract

A water-ballasted molded plastic barrier system incorporates barrier segments wherein each segment employs a sawtooth reflective design, designed to prevent the tire of a vehicle, impacting the barrier, from climbing up the side of the barrier segment. Adjacent barrier segments are attached together using an interlocking knuckle design, having a lug pin connection system. Wire rope cable assemblies are internally molded into each barrier segment to create an impenetrable cable fence. The wire rope cable assemblies include steel bushings which are molded into the interlocking knuckles to further strengthen the barrier system.

## Claims

### Claim 1

A method of making a barrier segment for use in creating a roadside barrier system, the method comprising:
disposing at least one wire rope cable, which is connected on an end thereof to a metallic bushing, within a mold tool; and
using the mold tool to mold a plastic hollow container, the molding step forming plastic outer walls defining the plastic hollow container and further forming a layer of plastic encapsulating the bushing and the end of wire rope cable connected thereto to form an integrally molded-in, leak-tight connection;
such that, when the molding step is completed, the wire rope cable and bushing are irremovably disposed within said plastic hollow container.

### Claim 2 (depends on 1)

The method as recited in claim 1, and further comprising a step of swaging the end of the wire rope cable to said bushing, thereby forming a cable loop around a periphery thereof.

### Claim 3 (depends on 2)

The method as recited in claim 2, and further comprising a step of swaging an opposed end of the wire rope cable to a second bushing, thereby connecting the second end to said second bushing and forming a second cable loop around a periphery thereof.

### Claim 4 (depends on 3)

The method as recited in claim 3, wherein the disposing step further comprises a step of stretching said wire rope cable and attached bushings across the mold, so that the cable is initially relatively taut, but becomes slack as the molding step is completed.

### Claim 5 (depends on 4)

The method as recited in claim 4, wherein the disposing step comprises disposing a plurality of wire rope cables and connected bushings within said mold tool.

### Claim 6 (depends on 1)

The method as recited in claim 1, wherein the using step comprises rotationally molding the barrier segment.

### Claim 7 (depends on 1)

The method as recited in claim 1, wherein said at least one wire rope cable comprises a plurality of wire rope cables, each of which are connected on an end thereof to a bushing, such that, when the molding step is completed, the wire rope cable and bushing assemblies are encapsulated in plastic and irremovably disposed within said plastic hollow container.

### Claim 8 (depends on 7)

The method as recited in claim 7, wherein each of the bushings are metallic.

### Claim 9 (depends on 1)

The method as recited in claim 1, wherein the metallic bushing has an enlarged step at each end thereof.