Vehicle crash barrier

Claim 2

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; and a mounting system coupled to the column and configured to mount the column alongside a roadway with the longitudinal axis extending substantially parallel to the roadway; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam.

Claim 3

The invention of claim 1 wherein the sheet of material comprises an expanded metal sheet.

Claim 4

The invention of claim 1 wherein the column comprises a pair of end caps, each secured to a respective end of the sheet of material.

Claim 5

The invention of claim 3 further comprising a retainer disposed within the column adjacent one of the end caps, said retainer secured to the sheet of material thereby retaining the foam in the column in the event the adjacent end cap is separated from the column as the column is collapsed during an impact.

Claim 6

The invention of claim 1 wherein the energy-absorbing element further comprises a second column disposed within and oriented generally parallel to the first mentioned column, said second column comprising a second sheet of material which defines a second array of perforations extending along and around the second column.

Claim 7

The invention of claim 5 wherein the first mentioned and second columns are eccentrically positioned one within the other thereby defining a preferred bending direction for the energy-absorbing element.

Claim 8

The invention of claim 1 wherein the column comprises at least one stiffener secured to the sheet of material of the column thereby selectively stiffening a portion of the column against bending.

Claim 9

The invention of claim 1 wherein the mounting system comprises means for rotatably mounting the energy-absorbing element to an obstruction positioned alongside a roadway to facilitate movement of the energy-absorbing element in a preferred bending direction.

Claim 10

The invention of claim 8 wherein the mounting means comprises: means for rigidifying the mounting means during an initial portion of axial collapse of the energy-absorbing element.

Claim 11

The invention of claim 1 wherein the vehicle crash barrier comprises a plurality of said energy-absorbing elements rigidly secured together and forming a beam, and wherein the mounting system comprises a mounting bracket secured to one of the energy-absorbing elements and cantilevering the beam substantially horizontally above a roadway.

Claim 12

The invention of claim 10 wherein the beam defines a length and a diameter, and wherein the ratio of length to diameter is greater than 3:1.

Claim 13

The invention of claim 11 wherein the ratio is at least 6:1.

Claim 14

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising a column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column; said energy-absorbing element and said column each defining a respective central longitudinal axis; said element and column longitudinal axes being offset with respect to one another such that the column is eccentrically positioned in the energy-absorbing element toward a first side of the energy-absorbing element along a transverse axis; said column having a sufficient rigidity to define a preferred bending direction for the energy-absorbing element; said preferred bending direction generally aligned with the transverse axis such that a redirecting force aligned with the transverse axis is applied to an axially impacting vehicle during axial collapse of the energy-absorbing element.

Claim 15

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising a column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column; said energy-absorbing element and said column each defining a respective central longitudinal axis; said element and column longitudinal axes being offset with respect to one another such that the column is eccentrically positioned in the energy-absorbing element toward a first side of the energy-absorbing element along a transverse axis; said column having a sufficient rigidity to define a preferred bending direction for the energy-absorbing element; said preferred bending direction generally aligned with the transverse axis such that a redirecting force aligned with the transverse axis is applied to an axially impacting vehicle during axial collapse of the energy-absorbing element.

Claim 16

The invention of claim 13 wherein the energy-absorbing element comprises a plurality of columns comprising a larger column and a smaller column, the smaller column disposed within the larger column, each column comprising a respective sheet of material which defines a respective array of perforations extending along and around the respective column, each column defining a respective column longitudinal axis, said column longitudinal axes being parallel and laterally spaced from one another along the transverse axis.

Claim 17

The invention of claim 14 wherein the plurality of columns comprises three columns.

Claim 18

The invention of claim 14 wherein at least one of said columns comprises a plurality of stiffeners comprising at least one first stiffener which braces the column against lateral bending to a greater extent than a second stiffener, said first stiffener offset with respect to the central column longitudinal axis toward the first side thereby increasing the redirecting force.

Claim 19

The invention of claim 14 wherein at least one of the columns comprises at least one stiffener, said at least one stiffener asymmetrically arranged with respect to the respective column longitudinal axis to increase the stiffness of the column toward the first side thereby increasing the redirecting force.

Claim 20

The invention of claim 13 wherein the sheet of material comprises an expanded metal sheet formed into a tube.

Claim 21

The invention of claim 13 wherein the column of the energy-absorbing element is configured with sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the energy-absorbing element along the element longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam.

Claim 22

The invention of claim 13 further comprising means for rotatably mounting the energy-absorbing element to an obstruction positioned alongside a roadway thereby facilitating movement of the energy-absorbing element in the preferred bending direction.

Claim 23

The invention of claim 20 wherein the mounting means comprises: means for rigidifying the mounting means during an initial portion of axial collapse of the energy-absorbing element.

Claim 24

The invention of claim 13 wherein the vehicle crash barrier comprises a plurality of said energy-absorbing elements rigidly secured together thereby forming a beam, and wherein the invention further comprises a mounting bracket secured to one of the energy-absorbing elements and cantilevering the beam substantially horizontally above a roadway.

Claim 25

The invention of claim 22 wherein the beam defines a length and a diameter, and wherein the ratio of length to diameter is greater than 3:1.

Claim 26

The invention of claim 23 wherein the ratio is at least 6:1.

Claim 27

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; a mounting system coupled to at least one of the energy absorbing elements for mounting the energy absorbing elements alongside a roadway with the longitudinal axis extending substantially parallel to the roadway; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the longitudinal axis is oriented generally parallel to an adjacent roadway and the crash barrier is struck at the forward end by an impacting vehicle.

Claim 28

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; a mounting system coupled to at least one of the energy absorbing elements for mounting the energy absorbing elements alongside a roadway with the longitudinal axis extending substantially parallel to the roadway; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the longitudinal axis is oriented generally parallel to an adjacent roadway and the crash barrier is struck at the forward end by an impacting vehicle.

Claim 29

The invention of claim 25 wherein the first energy-absorbing element comprises a smaller number of columns than the second energy-absorbing element.

Claim 30

The invention of claim 25 wherein at least selected ones of the columns each comprise a plurality of stiffeners, and wherein the stiffeners are arranged to provide increased axial stiffness to the second energy-absorbing element as compared to the first energy-absorbing element.

Claim 31

The invention of claim 27 wherein the stiffeners of at least one of the energy-absorbing elements are disposed asymmetrically about the longitudinal axis of the respective energy-absorbing element to selectively stiffen a first side of the energy-absorbing element to define a preferred bending direction for the energy-absorbing element.

Claim 32

The invention of claim 25 wherein the sheets of material of the columns each comprise a respective tubular sheet of expanded metal.

Claim 33

The invention of claim 29 wherein the perforations of the expanded metal sheets each define a major axis and a minor axis and

Claim 34

The invention of claim 25 wherein the column of at least the second energy-absorbing element is configured with sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the crash barrier and collapses the second energy-absorbing element along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam.

Claim 35

The invention of claim 25 wherein at least the second energy-absorbing element comprises stiffeners secured to a respective one of the columns and selectively axially stiffening the second energy-absorbing element with respect to the first energy-absorbing element.

Claim 36

The invention of claim 25 further comprising: means for rigidly securing adjacent ones of the energy-absorbing elements together to form a beam; and a mounting bracket secured to one of the energy-absorbing elements and cantilevering the beam substantially horizontally above a roadway.

Claim 37

The invention of claim 33 wherein the beam defines a length and a diameter, and wherein the ratio of length to diameter is greater than 3:1.

Claim 38

The invention of claim 34 wherein the ratio is at least 6:1.

Claim 39

The invention of claim 25 further comprising means for rotatably mounting a rearward one of the energy-absorbing elements to an obstruction positioned alongside a roadway.

Claim 40

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; wherein the column comprises a pair of end caps, each secured to a respective end of the sheet of material; a retainer disposed within the column adjacent one of the end caps, said retainer secured to the sheet of material thereby retaining the foam in the column in the event the adjacent end cap is separated from the column as the column is collapsed during an impact.

Claim 41

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; wherein the column comprises a pair of end caps, each secured to a respective end of the sheet of material; a retainer disposed within the column adjacent one of the end caps, said retainer secured to the sheet of material thereby retaining the foam in the column in the event the adjacent end cap is separated from the column as the column is collapsed during an impact.

Claim 42

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; wherein the energy-absorbing element further comprises a second column disposed within and oriented generally parallel to the first mentioned column, said second column comprising a second sheet of material which defines a second array of perforations extending along and around the second column.

Claim 43

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; wherein the energy-absorbing element further comprises a second column disposed within and oriented generally parallel to the first mentioned column, said second column comprising a second sheet of material which defines a second array of perforations extending along and around the second column.

Claim 44

The invention of claim 38 wherein the first mentioned and second columns are eccentrically positioned one within the other thereby defining a preferred bending direction for the energy-absorbing element.

Claim 45

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; and means for rotatably mounting the energy-absorbing element to an obstruction positioned alongside a roadway and facilitating movement of the energy-absorbing element in a preferred bending direction.

Claim 46

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: at least one energy-absorbing element comprising at least one column and a foam disposed within the column, wherein the column comprises a sheet of material which defines an array of perforations extending along and around the column, wherein the column defines a longitudinal axis extending along a length direction of the column; said column having sufficient rigidity such that, when an impacting vehicle having an initial kinetic energy impacts the energy-absorbing element and collapses the column along the longitudinal axis, the foam braces the column against buckling, and deformation of the column absorbs a greater fraction of the initial kinetic energy than does deformation of the foam; and means for rotatably mounting the energy-absorbing element to an obstruction positioned alongside a roadway and facilitating movement of the energy-absorbing element in a preferred bending direction.

Claim 47

The invention of claim 40 wherein the mounting means comprises: means for rigidifying the mounting means during an initial portion of axial collapse of the energy-absorbing element.

Claim 48

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein the first energy-absorbing element comprises a smaller number of columns than the second energy-absorbing element.

Claim 49

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein the first energy-absorbing element comprises a smaller number of columns than the second energy-absorbing element.

Claim 50

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured providing a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein at least selected ones of the columns each comprise a plurality of stiffeners, and wherein the stiffeners are arranged to provide increased axial stiffness to the second energy-absorbing element as compared to the first energy-absorbing element.

Claim 51

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured providing a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein at least selected ones of the columns each comprise a plurality of stiffeners, and wherein the stiffeners are arranged to provide increased axial stiffness to the second energy-absorbing element as compared to the first energy-absorbing element.

Claim 52

The invention of claim 43 wherein the stiffeners of at least one of the energy-absorbing elements are disposed asymmetrically about the longitudinal axis of the respective energy-absorbing element thereby selectively stiffening a first side of the energy-absorbing element to define a preferred bending direction for the energy-absorbing element.

Claim 53

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein the sheets of material of the columns each comprise a respective tubular sheet of expanded metal; wherein the perforations of the expanded metal sheets each define a major axis and a minor axis; wherein at least one of the expanded metal sheets of the first energy-absorbing element is oriented with the minor axes of the perforations parallel to the longitudinal axis; and wherein at least one of the expanded metal sheets of the second energy-absorbing element is oriented with the major axes of the perforations parallel to the longitudinal axis.

Claim 54

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein the sheets of material of the columns each comprise a respective tubular sheet of expanded metal; wherein the perforations of the expanded metal sheets each define a major axis and a minor axis; wherein at least one of the expanded metal sheets of the first energy-absorbing element is oriented with the minor axes of the perforations parallel to the longitudinal axis; and wherein at least one of the expanded metal sheets of the second energy-absorbing element is oriented with the major axes of the perforations parallel to the longitudinal axis.

Claim 55

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein at least the second energy-absorbing element comprises stiffeners secured to a respective one of the columns to selectively axially stiffen the second energy-absorbing element with respect to the first energy-absorbing element.

Claim 56

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; wherein at least the second energy-absorbing element comprises stiffeners secured to a respective one of the columns to selectively axially stiffen the second energy-absorbing element with respect to the first energy-absorbing element.

Claim 57

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; and means for rotatably mounting a rearward one of the energy-absorbing elements to an obstruction positioned alongside a roadway.

Claim 58

A vehicle crash barrier adapted to decelerate an impacting vehicle, said crash barrier comprising: a plurality of energy-absorbing elements arranged along a longitudinal axis from a forward end to a rearward end; at least first and second ones of the energy-absorbing elements each comprising at least one column defining a length direction substantially aligned with the longitudinal axis and a foam disposed within the column, each of said columns comprising a sheet of material which defines an array of perforations extending along and around the column; said first energy-absorbing element being closer to the forward end than is the second energy-absorbing element; said columns configured to provide a greater axial stiffness in the second than in the first energy-absorbing element such that the first energy-absorbing element is predisposed to begin to collapse axially before the second energy-absorbing element when the crash barrier is struck at the forward end by an impacting vehicle; and means for rotatably mounting a rearward one of the energy-absorbing elements to an obstruction positioned alongside a roadway.