Sound Wall Barrier System and Method of Constructing Same

This application claims priority from U.S. provisional patent application No. 63/575,582, entitled “SOUND WALL BARRIER SYSTEM AND METHOD OF CONSTRUCTING SAME”, filed on Apr. 5, 2024, the entire contents of which are hereby incorporated by reference herein.

The present disclosure generally relates to barrier systems with noise dampening capabilities, and in particular to barrier systems which can withstand impacts.

High traffic thoroughfares, such as highways, railroads, roadways, and the like, produce significant noise. In urban centers, buildings such as housing developments and businesses are frequently located proximate to the thoroughfares and as a result, may require protection from noise and require privacy. In some scenarios, sound walls or barriers (sometimes referred to as anti-noise or acoustic walls or barriers) may be positioned along stretches of through fares to deflect and/or dampen sound generated by vehicles and to provide privacy.

Sound wall barriers may be subjected to significant external forces once constructed. For example, vehicles (e.g. cars, SUVs, and heavy transport trucks) may lose control and impact sound wall barriers. Such impacts can cause catastrophic damage to sound wall barriers, including the tipping over and/or destruction of sound wall barriers. In some scenarios, the structural strength of a sound wall barrier system may be enhanced by using larger, stronger materials. In some scenarios, the likelihood of vehicular impacts may be reduced by placing sound wall barriers further away from the thoroughfare. However, in some settings, particularly urban settings, real estate or land may be limited and it may be unfeasible to construct sound wall barriers having larger dimensions or to place barriers a greater distance away from thoroughfares.

Accordingly, there is a need for sound wall barrier systems which provide increased structural resilience to impacts and which can be accommodated without requiring significantly more space.

In one aspect, the present disclosure describes a sound wall barrier system. The system includes: a first barrier having a first barrier end including a first recessed cavity, the first recessed cavity defined by an angled side and a recessed back surface; a first elongate post at the first barrier end positioned proximal to the first recessed cavity, the first elongate post including a central web and a post flange coupled to the central web; and a first angled flange coupled to the first barrier within the first recess cavity, wherein the first angled flange and the recessed back surface circumscribe at least a portion of the post flange.

In some embodiments, the first barrier includes an opposing barrier end opposite the first barrier end, the opposing barrier end having an opposing recessed cavity, wherein the opposing recessed cavity is defined by an angled side and a recessed back surface.

In some embodiments, the sound wall barrier system includes: a second elongate post at the opposing barrier end positioned proximal to the opposing recessed cavity, the second elongate post positioned substantially parallel to the first elongate post; and a railing coupled to at least one of the first elongate post and the second elongate post, the railing extending in a direction from the first elongate post to the second elongate post.

In some embodiments, the sound wall barrier system includes: a set of nested hollow steel sections including an inner hollow steel section and an outer hollow steel section, wherein one of the inner hollow steel section and the outer hollow steel section is coupled to the railing and the other of the inner hollow steel section and the outer hollow steel section is coupled to the first elongate post.

In some embodiments, the inner hollow steel section and the outer hollow steel section are respectively welded to one of the railing and the first elongate post.

In some embodiments, the railing is at least one of a hollow steel section or a C-channel beam.

In some embodiments, the sound wall barrier system includes: a plurality of sound wall panels received between the first elongate post and the second elongate post, wherein the railing is referenced based on a railing plane that is offset to a plane of the plurality of sound wall panels.

In some embodiments, the sound wall barrier system includes: a footing positioned in a grade, the footing configured to encase the first elongate post.

In some embodiments, the first angled flange is coupled to the angled side of the first recessed cavity.

In some embodiments, the first angled flange is coupled to the angled side based on a screw fastener.

In some embodiments, the portion of the post flange circumscribed by the first angled flange and the recessed back surface is unfixed to the first angled flange and the recessed back surface.

In some embodiments, the sound wall barrier system includes: a second barrier having a second barrier end positioned adjacent the first barrier, the second barrier having a second recessed cavity, the second recessed cavity defined by an angled side and a recessed back surface, wherein the second barrier end is positioned adjacent the first barrier end to provide a collective recessed cavity, and wherein the post flange is positioned within the collective recessed cavity.

In some embodiments, the first barrier includes a first loop protruding from the first barrier end, and wherein the second barrier includes a second loop complementary to the first loop, the second loop protruding from the second barrier end.

In some embodiments, the sound wall barrier system includes a second angled flange coupled to the second barrier within the second recessed cavity.

In some embodiments, the first barrier is a concrete modular barrier.

In some embodiments, the first angled flange includes a first portion of the first angled flange that may be configured at a 45-degree angle relative to a second portion of the first angled flange.

In this respect, before explaining at least one embodiment in detail, it is to be understood that the embodiments are not limited in application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

Many further features and combinations thereof concerning embodiments described herein will appear to those skilled in the art following a reading of the present disclosure.

The foregoing summary, as well as the following detailed description of certain examples will be better understood when read in conjunction with the appended drawings. As used herein, an element or feature introduced in the singular and preceded by the word “a” or “an” should be understood as not necessarily excluding the plural of the elements or features. Further, references to “one example” or “one embodiment” are not intended to be interpreted as excluding the existence of additional examples or embodiments that also incorporate the described elements or features. Moreover, unless explicitly stated to the contrary, examples or embodiments “comprising” or “having” or “including” an element or feature or a plurality of elements or features having a particular property may include additional elements or features not having that property. Also, it will be appreciated that the terms “comprises”, “has”, “includes” means “including but not limited to” and the terms “comprising”, “having” and “including” have equivalent meanings.

As used herein, the term “and/or” can include any and all combinations of one or more of the associated listed elements or features.

It will be understood that when an element or feature is referred to as being “on”, “attached” to, “affixed” to, “connected” to, “coupled” with, “contacting”, etc. another element or feature, that element or feature can be directly on, attached to, connected to, coupled with or contacting the other element or feature or intervening elements may also be present. In contrast, when an element or feature is referred to as being, for example, “directly on”, “directly attached” to, “directly affixed” to, “directly connected” to, “directly coupled” with or “directly contacting” another element of feature, there are no intervening elements or features present.

It will be understood that spatially relative terms, such as “under”, “below”, “lower”, “over”, “above”, “upper”, “front”, “back” and the like, may be used herein for ease of description to describe the relationship of an element or feature to another element or feature as illustrated in the figures. The spatially relative terms can however, encompass different orientations in use or operation in addition to the orientation depicted in the figures.

Reference herein to “example” means that one or more feature, structure, element, component, characteristic and/or operational step described in connection with the example is included in at least one embodiment and/or implementation of the subject matter according to the subject disclosure. Thus, the phrases “an example,” “another example,” and similar language throughout the subject disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example.

Reference herein to “configured” denotes an actual state of configuration that fundamentally ties the element or feature to the physical characteristics of the element or feature preceding the phrase “configured to.”

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of a lower-numbered item (e.g., a “first” item) and/or a higher-numbered item (e.g., a “third” item).

As used herein, the terms “approximately”, “about”, “substantially”, and “generally” represent an amount close to the stated amount or a deviation from a strict definition that still results in the desired function or result being performed or achieved. For example, the terms “approximately”, “about”, “substantially”, and “generally” may refer to an amount or deviation that is within engineering tolerances and that would be readily appreciated by a person of ordinary skill in the art.

Various aspects of preferred embodiments of sound wall barrier systems according to the disclosure are described herein with reference to the drawings.

illustrate perspective views of an example sound wall barrier system, in accordance with some embodiments. As depicted, systemincludes one or more interconnected barriers, a plurality of postswhich are located in the vicinity of the point of interconnection between barriersand extend upwardly from respective footings, sound wall panelsextending between posts, and one or more railingsextending between posts. In some embodiments, systemmay be placed in the vicinity of a thoroughfare. In some embodiments, the side of systemwhich includes railings(hereinafter referred to as the noise-facing side) may be facing towards the thoroughfare. Sound wall panelsmay be operable to deflect and/or absorb noise generated by vehicles and/or objects in the thoroughfare, which may be beneficial for reducing noise levels on the back side of the system. In some embodiments, postmay be encased in a footing, which may be inserted into the ground to provide additional stability to system. In some embodiments, footingsmay be made of concrete. In some embodiments, sound wall panelsmay be made of polyvinyl chloride, commonly referred to as PVC.

is a perspective view facing a back sideof the example sound wall barrier system of. Similarly,is a perspective view facing a back sideof the example sound wall barrier system of. In some embodiments, the back sideof systemfaces away from a roadway and is the side opposite to the noise-facing side.is a front view of the traffic-facing sideof the example sound wall barrier system of.is a front view of the traffic-facing sideof the example sound wall barrier system of.is a top view of the example sound wall barrier system of.is a top view of the example sound wall barrier system of.E is a bottom view of the example sound wall barrier system of.is a top view of the example sound wall barrier system of.is a side view of the example sound wall barrier system of.is a side view of the example sound wall barrier system of.is a side view of the example sound wall barrier system of.is a side view of the example sound wall barrier system of.

As depicted in, systemmay include a plurality of barrierswhich are interconnected. In some embodiments, barriermay be a traffic barrier including, but not limited to, a Jersey barrier, a K-rail barrier, an Ontario Tall Wall, or any other suitable barrier. In some embodiments, postmay be coupled to one or more barriers.

illustrate perspective views of a back sideof system.shows postcoupled to one or more barriersby two angled flanges,. FIG.G shows postcoupled to one or more barriers by one angled flange. In general, at least one flange may be used to couple barrierto post.

are perspective views facing the back sideof systemwith all other elements omitted other than barriersfor simplicity. As depicted, each barriermay include a top, a back, an angled side, and a recessed back. In some embodiments, recessed backmay be parallel to back. In other embodiments, recessed backand backmight not be parallel. The combination of angled sideand recessed backmay be referred to collectively herein as recessed cavity.

are perspective views of the back sideof systemwith all other elements omitted other than barriersand postfor simplicity. As depicted, postcomprises a first flangeand a second flangeconnected by a central web. In some embodiments, postmay be a so-called W-beam (sometimes referred to as a W-section or a W-shape). In other embodiments, postmay be an I-beam, an H-beam, or any other suitable configuration having two flanges connected by a central webbing. As depicted in, a retaining flangeis affixed to central webof post. In some embodiments, the retaining flangeis welded to central web. In some embodiments, the retaining flangemay be bolted to central web. In some embodiments, retaining flangemay be parallel to first flangeand second flange.

As described with reference to, postis coupled to one or more barriersvia one or more angled flanges,.are perspective views of systemomitting sound wallsand omitting a portion of postfor simplicity.is a top view of the embodiment depicted in.is a top view of the embodiment depicted in. As shown inand, angled flangeis secured to angled sideand a portion of angled flangeprotrudes between first flangeand retaining flangeof post. In some embodiments, the angled flangemay include a first portion coupled to the angled sideby a fastenerand a second portion extending from the first portion. As illustrated in, the second portion of the angled flangemay extend away from the angled sidesurface akin to a cantilever portion. In some embodiments, the second portion of the angled flangeand a received back surfacemay circumscribe at least a portion of the first flangeof the post. In some embodiments, an angle between the described first portion and the second portion of the angled flangemay be approximately 45 degrees. In some embodiments, the angle between the first portion and the second portion may be complementary to an angle between the angled sidesurface and the recessed backsurface, as illustrated in. Other angles between the described first portion and the second portion of the angled flangemay be contemplated such that the angled flangeand the recessed backsurface may collectively circumscribe at least a portion of the post, such as a portion of the first flange.

In some embodiments, the angled flangemay not be in physical contact with the first flangeor any other portion of the post, such that the postmay move relative to the angled flangeand the recessed backsurface when a vehicle or other object impacts the sound wall barrier system.

As shown in, the systemmay comprise two angled flangesand. As shown in, the systemmay comprise one angled flange. In some embodiments, angled flange,may be secured to angled sideof barrierby a fastener. In some embodiments, barriermay include an anchorpositioned on angled side, so as to receive fastenermore securely. In some embodiments, the anchormay be a threaded anchor and fastenermay be correspondingly threaded to engage with the threading of threaded anchorto further secure the connection between angled flange,and barrier. In some embodiments, a portion of angled flange,may be embedded within barrierrather than fastened thereto. In some embodiments, an embedded flange having a flat shape (to be contrasted with the kinked shape of angled flange,depicted in) may have a portion embedded in barrier(e.g. entering at a location on angled side) which may enable a protruding portion from angled sidebetween first flangeand retaining flangeto act as a cantilever. In some embodiments, an embedded flange may be secured to an anchor within barrierto provide additional strength. It will be appreciated that there are many different ways of securing a flange to barrier(whether through the use of fasteners, embedding, or any combination thereof).

As depicted in, a second angled flangemay be positioned on angled side. As depicted, angled flangeis positioned vertically higher than angled flange, and includes 3 holes for 3 respective fasteners. It will be appreciated that the embodiment depicted inare merely examples and that embodiments which have as few as 1 hole to more than 3 holes are contemplated. In some embodiments, angled sidemay include a corresponding number of threaded anchors to match the number of holes in angled flange. It will be appreciated that in other embodiments, first angled flangemay include more than one hole for receiving fasteners, and that angled sidemay be designed to generally include a number of anchors (which may optionally be threaded anchors) which match the number of holes on angled flange, such that fastenersmay be inserted into each hole and secured to the threaded anchors. Of course, in some embodiments, fastenersmight not be inserted into every hole on angled flanges,, and the number of threaded anchors on angled sidemight not necessarily match the number of holes on angled flanges,.

As depicted in, first flangeof postmay be in close proximity with recessed backsof the two barriersdepicted. In some embodiments, first flange may be in physical contact with recessed backs. In some embodiments, although first flangemay be in physical contact with recessed backs, first flange might not be secured or attached to recessed backs. In some embodiments, the protruding portion of angled flanges,is present between first flangeof postand retaining flangeof post. As depicted, the protruding portion of angled flanges,may not be not in physical contact with first flangeor retaining flangeof post. During periods of high wind and/or impacts to system, postmay move and/or warp and may come into contact with one or more of angled flanges,.

In some embodiments, the configuration of angled flanges,to interconnect barrierswith postsmay result in postbeing able to withstand greater torsional buckling stress relative to previously known configurations without angled flange(s),. Given that postmay bear less torsional buckling stress, the use of angled flange(s),may allow for the physical dimensions of one or more of first flange, second flange, web, and/or retaining flangeto be reduced while providing similar performance and resistance to torsional buckling stress. This may be beneficial in that the size of components of postmay be reduced, which results in lower material costs, as well as the systemoverall taking up less space and potentially being usable in scenarios in which there is limited space for sound wall barrier systems. For example, since angled flanges,may not be in direct contact to provide support to post, the postcan laterally deflect and may have some freedom of movement within the recessed cavity, which may allow the postto slide laterally, which may help reduce the load in situations such as lateral torsional buckling.

In other embodiments (such as the leftmost postdepicted in), first flangeof postmay be in contact with a recessed backof a single barrierand secured by angled flanges,on a single side of web. In such embodiments, postmay have less structural resilience and might not be able to withstand as much torsional buckling stress relative to embodiments in which postis placed between two barriers, and angled flanges,are present on both sides of web.

As depicted in, and more particularly in, sound panelsmay be positioned between first flangeand retaining flangeand may extend between a first postand a second post. In some embodiments, a plurality of sound panelsmay be stacked vertically upward beginning from the topof barrier. In some embodiments, the distance between first flangeand retaining flangemay be selected so as to substantially match a thickness of sound panels. This may provide a benefit of sound panelsbeing securely fixed at each post, so as to provide greater structural integrity and reduce the likelihood of sound panels rattling or otherwise moving during periods of high winds, and the like.

Returning to, in some embodiments, systemmay include a plurality of barrierswhich are interconnected. In some embodiments, barriersmay be interconnected in a manner which enhances the structural strength of the overall system, and may facilitate distribution of forces during impacts (e.g. with vehicles) against barriers.is a perspective view of a first side of a first barrieromitting post, footing, and a second barrierfor simplicity. As depicted, barrierincludes a vertical notchwhich extends from topto the bottom of barrierIn the embodiment depicted, vertical notchis semicircular, but it will be appreciated that other embodiments may incorporate different shapes for vertical notch. It will be further appreciated that vertical notchneed not have a consistent depth or radius through the entire height of barrierand may have a variable shape as the case may be. The embodiment depicted inis an example embodiment and is not intended to be limiting, and other barrier configurations are contemplated.

As depicted in, barrierfurther includes upper notchand lower notch. As depicted, notches,are rectangular in shape and extend from the front of barrierall the way through the back. Although the notches are depicted as rectangular in shape in the Figures, it will be appreciated that the embodiments depicted are merely examples, and other shapes for notches,may be possible. As will be appreciated from, when two barriersare arranged side by side or in close proximity, vertical notchesmay align to form a cavity or space which is sufficiently dimensioned to receive fastener.

As depicted in, barrierincludes upper taband lower tabon a first end. In some implementations, each of upper taband lower tabincludes two apertureswhich are axially aligned, so as to allow a fastenerto be inserted therethrough. In some implementations, as shown in, each of upper taband lower tabmay include a bar loop connection having a single aperture. A fastenercan be inserted through the bar loop. Although two separate fasteners(one for upper tab, and another for lower tab) are depicted in, in other embodiments a single fastener(e.g. a bolt having sufficient length) may extend through both upper taband lower tab, as depicted in. As shown in, a second end of barriermay include upper taband lower tabIt will be appreciated that althoughdepicts two separate barriersthe same principles may apply to a single barrier. In other words, a first end of barriermay include upper taband lower taband a second side opposite the first end of barriermay include upper taband lower tab

As depicted in, upper tabmay be located at a height which is vertically higher than upper tabIn some embodiments, upper tabmay be located at a height which is in relatively close proximity to upper tab(e.g. a vertical distance of about 12-25 millimeters, though it will be appreciated that other distances are contemplated). In some embodiments, the height difference between upper taband upper tabmay be sufficiently small to ensure that fasteneris acting as a pin connection (i.e. without a bending moment).