Hot asphalt pavement installation method utilizing solid phase autoregenerative cohesion

• US 10,081,920 B2
• Filed: 09/29/2016
• Issued: 09/25/2018
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: William B. Coe
• Original Assignee: William B. Coe
• Inventors: Coe, William B.
• Primary Examiner(s): Hartmann, Gary S
• Application Number:
  US15/280,945
• Publication Number:
  US 20170058468A1
• Time in Patent Office: 726 Days
• Field of Search: 404 79, 404 95
• CPC Class Codes: C08L 2555/34 Recycled or waste materials, e.g. reclaimed bitumen, asphalt, roads or pathways, recycled roof coverings or shingles, recycled aggregate, recycled tires, crumb rubber, glass or cullet, fly or fuel ash, or slag
• CPC Class Codes: C08L 2555/86 Polymers containing aliphatic hydrocarbons only, e.g. polyethylene, polypropylene or ethylene-propylene-diene copolymers
• CPC Class Codes: C08L 95/005 Aqueous compositions, e.g. emulsions
• CPC Class Codes: C09D 123/22 Copolymers of isobutene; Butyl rubber ; Homo- or copolymers of other iso-olefines
• CPC Class Codes: C09D 195/005 Aqueous compositions, e.g. emulsions
• CPC Class Codes: C10C 3/002 by thermal means
• CPC Class Codes: C10C 3/10 Melting
• CPC Class Codes: E01C 11/005 Methods or materials for repairing pavings E01C7/35 takes precedence; for concrete coverings E01C7/147; for bituminous coverings E01C7/187; devices for repair works E01C23/06; repairing bridge floorings E01D22/00
• CPC Class Codes: E01C 11/16 Reinforcements as anchoring elements between layers E01C7/145, E01C7/185, E01C7/325 ; for building in general E04C
• CPC Class Codes: E01C 19/002 Apparatus for preparing and placing the materials and for consolidating or finishing the paving
• CPC Class Codes: E01C 19/15 for laying-down uncoated stone or similar materials, or for striking-off or spreading same without compacting, e.g. for crushed rock base courses, sand cushions for paving E01C19/466 , E01C19/52 take precedence; distributing E01C19/20; laying down and rolling E01C19/482
• CPC Class Codes: E01C 19/23 Rollers therefor; Such rollers usable also for compacting soil E01C19/41, E01C19/43, E01C19/52, E01C23/065 take precedence; specially adapted for agricultural purposes A01B29/00; garden rollers A01G20/35; making or maintaining surfaces of snow or ice E01H4/00; solely for soil compaction E02D3/026
• CPC Class Codes: E01C 21/00 Apparatus or processes for surface soil stabilisation for road building or like purposes, e.g. mixing local aggregate with binder recycling in place or on the road involving soil stabilisation E01C23/065 ; stabilising soil under existing surfacing E01C23/10; soil-conditioning or soil-stabilising materials C09K17/00; soil consolidation in general E02D3/12
• CPC Class Codes: E01C 23/03 Arrangements for curing paving; Devices for applying curing means; Devices for laying prefabricated underlay, e.g. sheets, membranes reinforcing elements E01C23/04; Protecting paving under construction or while curing, e.g. use of tents road barriers E01F13/00
• CPC Class Codes: E01C 23/04 Devices for laying inserting or positioning reinforcing elements or dowel bars with or without joint bodies installing or inserting joint bodies per se E01C23/023, E01C23/026; Removable supports for reinforcing or load transfer elements non- removable supports therefor E01C11/02 E01C11/16; side forms adapted to supporting reinforcement E01C19/50; Devices, e.g. removable forms, for making essentially horizontal ducts in paving, e.g. for prestressed reinforcements
• CPC Class Codes: E01C 23/06 Devices or arrangements for working the finished surface working freshly laid paving E01C19/42 - E01C19/44, E01C23/02; mining picks E21C35/18; Devices for repairing or reconditioning the surface of damaged paving; Recycling in place or on the road
• CPC Class Codes: E01C 23/065 Recycling in place or on the road, i.e. hot or cold reprocessing of paving in situ or on the traffic surface, with or without adding virgin material or lifting of salvaged material; Repairs or resurfacing involving at least partial reprocessing of the existing paving in situ mixing of hydraulic cement concrete E01C19/025; apparatus for in-plant recycling E01C19/1004, E01C19/1036
• CPC Class Codes: E01C 23/07 Apparatus combining measurement of the surface configuration of paving with application of material in proportion to the measured irregularities measuring means only E01C23/01 G01B
• CPC Class Codes: E01C 23/10 for raising or levelling sunken paving; for filling voids under paving; for introducing material into substructure consolidating soil in general E02D3/12
• CPC Class Codes: E01C 23/14 for heating or drying foundation, paving, or materials thereon, e.g. paint E01C23/03 takes precedence; heating or drying devices incorporated in the paving E01C11/26; surface soil stabilisation by fusing, calcining or burning soil in situ E01C21/02; for street cleaning E01H1/08; melting snow or ice on surfacing E01H5/10
• CPC Class Codes: E01C 7/187 : Repairing bituminous covers, e.g. regeneration of the covering material in situ, application of a new bituminous topping application of thin surface layers with other binders E01C7/35; repairing pavings in general E01C11/005
• CPC Class Codes: E01C 7/36 : by subjecting soil to stabilisation E01C7/06 takes precedence; foundations E01C3/04; soil conditioning or soil stabilising materials C09K17/00; soil stabilisation devices for road construction E01C21/00
• CPC Class Codes: G21K 5/02 : having no beam-forming means
• CPC Class Codes: H05B 6/48 : Circuits
• CPC Class Codes: H05B 6/54 : Electrodes
• CPC Class Codes: H05B 6/62 : Apparatus for specific applications
• CPC Class Codes: H05B 6/80 : Apparatus for specific applications stoves or ranges F24C7/02

Abstract

A method for installing hot asphalt pavement includes heating an aggregate to a temperature of from about 350° F. to about 400° F. using an emitter comprising a birefringent material, the emitter generating electromagnetic radiation having a wavelength of from 2 microns to 1 millimeter, wherein the aggregate is a recycled asphalt pavement; adding the aggregate to an asphalt in a mill to yield a mixture of aggregate with baked-on asphalt; laying the mixture down over a base to form a first layer of lift; and compacting the first layer.

Claims

1. A method for installing hot asphalt pavement, comprising:

providing an aggregate, wherein the aggregate comprises recycled asphalt pavement;

heating the aggregate to a temperature of from about 350°

F. to about 400°

F. using an emitter, wherein the emitter comprises a birefringent material through which electromagnetic radiation generated by the emitter passes, wherein the emitter generates electromagnetic radiation having a wavelength of from about 1 nm to 5 mm;

adding the aggregate to an asphalt in a mill to yield a mixture of aggregate with baked-on asphalt;

laying the mixture down over a base to form a first layer of lift; and

compacting the first layer, whereby a hot asphalt pavement is installed.

2. The method of claim 1, wherein a temperature of the mixture when laid down to form the first layer is about 140°

F.

3. The method of claim 1, further comprising laying down and compacting one or more additional layers of lift atop the first layer of lift.

4. The method of claim 3, wherein the first layer of lift and the one or more additional layers of lift have a thickness of approximately 12 inches.

5. The method of claim 3, wherein no primer or additional material is put between the layers of lift.

6. The method of claim 1, wherein the base is an existing asphalt or concrete pavement in need of repair.

7. The method of claim 1, wherein the base is an earthen base covered with gravel that has been graded and compacted.

8. The method of claim 1, wherein the mixture comprises 95% aggregate and 5% asphalt.

9. The method of claim 1, wherein the aggregate comprises particles having a diameter of from ¼

inches to ⅜

inches.

10. The method of claim 1, wherein the first layer provides a 2 inch to 3 inch lift.

11. The method of claim 1, wherein the asphalt comprises a rubber polymer.

12. The method of claim 1, wherein the asphalt added to the aggregate is in a form of an elastomer composition comprising butyl rubber, diene modified asphalt, and an environmentally hardened bioresin.

13. The method of claim 1, wherein the elastomer composition comprises less than 1% perflurocarbons as a volatile component.

14. The method of claim 1, wherein the elastomer composition comprises no perflurocarbons as a volatile component.

15. The method of claim 1, wherein the emitter is a panel comprising a serpentine wire and wherein the birefringent material is a micaceous material.

16. The method of claim 1, wherein the emitter produces electromagnetic radiation with a power density of from 0.47 to 2.33 W/cm² or from 133 to 664 (ft·

lb_f/min)/in².

17. The method of claim 1, wherein the electromagnetic radiation has a wavelength of 2 microns to 1 millimeter.

18. The method of claim 1, wherein the emitter panel is configured to emit electromagnetic radiation at a wavelength of from about 20 nm to about 100 microns.

19. The method of claim 1, wherein the emitter panel is configured to emit electromagnetic radiation at a wavelength of from about 20 microns to about 100 microns.