Pavement repair system

• US 10,724,183 B2
• Filed: 06/14/2019
• Issued: 07/28/2020
• 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): Addie, Raymond W
• Application Number:
  US16/442,320
• Publication Number:
  US 20190301105A1
• Time in Patent Office: 410 Days
• Field of Search: 404 75, 404 77, 404 79, 404 95
• CPC Class Codes: B29C 63/02 using sheet or web-like material B29C63/26 and B29C63/38 take precedence
• CPC Class Codes: B29K 2021/003 Thermoplastic elastomers
• CPC Class Codes: B29L 2031/732 Floor coverings piles carpets B29L2031/7652; for vehicles B29L2031/3017
• CPC Class Codes: B32B 18/00 Layered products essentially comprising ceramics, e.g. refractory products
• CPC Class Codes: B32B 2037/1253 curable adhesive
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2272/00 Resin or rubber layer comprising scrap, waste or recycling material
• CPC Class Codes: B32B 2310/0806 using electromagnetic radiation
• CPC Class Codes: B32B 2315/06 Concrete
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 37/16 with all layers existing as coherent layers before laminating
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08L 21/00 Compositions of unspecified rubbers
• CPC Class Codes: C08L 2205/03 containing three or more polymers in a blend
• CPC Class Codes: C08L 2555/84 Polymers comprising styrene, e.g. , polystyrene, styrene-diene copolymers or styrene-butadiene-styrene copolymers
• CPC Class Codes: C08L 2555/86 Polymers containing aliphatic hydrocarbons only, e.g. polyethylene, polypropylene or ethylene-propylene-diene copolymers
• CPC Class Codes: C08L 95/00 Compositions of bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: C08L 95/005 Aqueous compositions, e.g. emulsions
• CPC Class Codes: C09D 119/003 : Precrosslinked rubber; Scrap rubber; Used vulcanised rubber
• CPC Class Codes: C09D 195/00 : Coating compositions based on bituminous materials, e.g. asphalt, tar, pitch
• CPC Class Codes: C09J 119/003 : Precrosslinked rubber; Scrap rubber; Used vulcanised rubber
• CPC Class Codes: C09J 195/005 : Aqueous compositions, e.g. emulsions
• 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 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 19/48 : for laying-down the materials and consolidating them, or finishing the surface , e.g. slip forms therefor, forming kerbs or gutters in a continuous operation in situ E01C19/002, E01C23/065 take precedence; devices for guiding or controlling the machines along a predetermined path E01C19/004
• CPC Class Codes: E01C 19/4853 : Apparatus designed for railless operation, e.g. crawler-mounted, provided with portable trackway arrangements
• 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 23/06 : 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 23/14 : 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 2301/10 : Heated screeds
• 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 7/26 : mixed with other materials, e.g. cement, rubber, leather, fibre fibrous material reinforcements for bituminous paving E01C11/165
• CPC Class Codes: E01C 7/358 : with a combination of two or more binders according to groups E01C7/351 - E01C7/356
• CPC Class Codes: E01D 19/08 : Damp-proof or other insulating layers; Drainage arrangements or devices ; Bridge deck surfacings bridge decks per se E01D19/125
• CPC Class Codes: E01D 22/00 : Methods or apparatus for repairing or strengthening existing bridges electrochemical desalination or re-alkalisation C04B41/00; Methods or apparatus for dismantling bridges
• CPC Class Codes: E02D 31/06 : against corrosion by soil or water
• CPC Class Codes: E04B 1/66 : Sealings damp-proof courses E04B1/644; fire-proof sealings E04B1/948; additions of anti-leak properties to plaster C04B; bituminous sealing masses C08L95/00; sealings for hydraulic engineering work in general E02B3/16; against ground humidity or ground water E02D31/02; coverings against rain or other precipitations of the atmosphere E04D; composition of material or manufacture of sealing foils, see the relevant classes for these foils

Abstract

A pavement repair system utilizes solid phase auto regenerative cohesion and homogenization by liquid asphalt oligopolymerization technologies. The system is suitable for use in repairing asphalt pavement, including pavement exhibiting a high degree of deterioration (as manifested in the presence of potholes, cracks, ruts, or the like) as well as pavement that has been subject to previous repair and may comprise a substantial amount of dirt and other debris (e.g., chipped road paint or other damaged or disturbed surfacing materials). A system utilizing homogenization by liquid asphalt oligopolymerization is suitable for rejuvenating or repairing aged asphalt, thereby improving properties of the paving material.

Claims

1. An emitter system for repairing asphalt pavement, comprising:

a structural frame insulated with a layer of a high-density ceramic and supporting at least one wire positioned between the high-density ceramic and a material exhibiting biaxial birefringence, wherein the emitter is configured such that, in use, energy generated by the emitter passes through the material exhibiting biaxial birefringence and impinges on an asphalt pavement, wherein the emitter is configured to produce energy with a 1000-10000 nm peak wavelength.

2. The emitter of claim 1, wherein the structural frame is a metal frame comprising one or more beams attached to one or more wheels, and wherein the structural frame is configured to prevent bending, sagging, or twisting even while traversing uneven terrain.

3. The emitter of claim 1, further comprising a power interrupting mechanism and a positioning system.

4. The emitter of claim 1, further comprising a power distribution device disposed on at least a part of the frame, wherein the power distribution device comprises one or more circuit breakers or other power interrupting mechanisms.

5. The emitter of claim 1, wherein the emitter is sized so as to irradiate a standard lane width of asphalt pavement in a single pass.

6. The emitter of claim 1, further comprising a power source configured to supply electrical power to the emitter, wherein the power source is a portable generator.

7. The emitter of claim 6, wherein the portable generator is a diesel generator configured to deliver at least 250 kW.

8. The emitter of claim 1, wherein the emitter is a panel in a shape of a square or a rectangle having dimensions of approximately 12 inches by approximately 24 inches, and wherein the panel is adapted to be arranged in an array wherein each panel in the array abuts an adjacent panel, and wherein each panel in the array is connected in parallel or in serial with other emitter panels.

9. The emitter of claim 8, wherein the array is approximately 12 feet wide, 8 feet long, and approximately 2 feet high.

10. The emitter of claim 8, further comprising a vehicle configured to pull the array and the power source over an asphalt pavement.

11. A method for repairing an asphalt pavement, comprising:

passing the emitter of claim 1 over an asphalt pavement in need of repair, wherein the emitter radiates energy into the asphalt pavement so as to heat the asphalt pavement to a depth of at least 2 inches, wherein a temperature differential throughout a top two inches of the asphalt pavement is 100°

F. or less, wherein a highest temperature in the top two inches of the asphalt pavement does not exceed 300°

F., and wherein a minimum temperature in the top two inches of the asphalt pavement is at least 200°

F., whereby voids and interstices in the asphalt pavement are disturbed without dehydrogenation of the asphalt in the asphalt pavement, and whereby oligomers present in the asphalt of the asphalt pavement are linked together into longer polymer chains, whereby ductility of the asphalt is improved.

12. The method of claim 11, wherein the asphalt pavement is damaged asphalt pavement, the method further comprising, before passing the emitter over the asphalt:

preparing a surface of the damaged asphalt pavement comprising aged asphalt by filling in deviations from a uniform surface plane with dry aggregate and compacting the dry aggregate; and

applying a reactive asphalt emulsion to the prepared surface, whereby the reactive emulsion penetrates into cracks and crevices in the damaged asphalt pavement and into areas filled with the dry aggregate, wherein the reactive asphalt emulsion comprises butyl rubber, a diene modified asphalt, and an environmentally hardened bioresin, and wherein the reactive asphalt emulsion contains less than 1% perflurocarbons as volatile components.

13. The method of claim 12, further comprising removing road reflectors, thermoplastic imprinting, and safety devices by mechanically removing prior to filling in deviations.

14. The method of claim 12, wherein the reactive asphalt emulsion further comprises a 10,000 to 100,000 molecular weight grafted or ungrafted polyisobutylene and a 10,000 to 100,000 molecular weight grafted or ungrafted styrene-butadiene-styrene.

15. The method of claim 12, wherein the dry aggregate is pre-coated with an elastomeric composition, and wherein the reactive asphalt emulsion is at least partially cured so as to yield dry, free-flowing coated asphalt.

16. The method of claim 12, wherein a temperature differential throughout a top two inches of asphalt pavement is 100°

F. or less.

17. The method of claim 12, wherein the energy comprises wavelengths of from 1 nm to 5 mm.

18. The method of claim 12, wherein the energy comprises wavelengths of from 2 nm to 5 mm.

19. The method of claim 12, wherein the oligomers possess 2-150 repeating units.

20. The method of claim 12, further comprising, after passing the emitter over the asphalt:

allowing the pavement to cool to below 240°

F.; and

applying a compacting roller to the asphalt pavement to minimize voids and surface irregularities, wherein the asphalt is at a temperature no lower than 150°

F., whereby a density of the compacted asphalt pavement is similar to that of virgin asphalt pavement.

21. The method of claim 12, wherein the energy has a peak wavelength of 1000-10000 nm peak wavelength.