Process and machinery for applying a layer of asphalt to a surface

• US 20050175412A1
• Filed: 03/07/2005
• Published: 08/11/2005
• Est. Priority Date: 04/11/2002
• Status: Active Grant

• Current Assignee: Enviro-Pave, Inc.
• Original Assignee: Enviro-Pave, Inc.
• Inventors: Lloyd, Peter
• Granted Patent: US 7,077,601 B2
• Time in Patent Office: Days
• US Class Current: 404/77
• 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 2301/50 Methods or devices for preventing dust by spraying or sucking

Abstract

A process and device for the recycling of asphalt including at least one one preheater unit. The preheater having a heater, scarifying rakes, and a bin to dispense aggregate. Also include is a recycling machine having a heater, scarifying rakes, a plurality of extension mills, a main mill, as well as a pug mill having first and second downwardly rotating rotors, the pug mill mixes asphalt and liquid additives together to form a homogenous mix; and at least one screed for laying the homogeneously mixed asphalt to grade.

Claims

1. A process for the recycling of asphalt comprising:

supplying at least one preheater unit, said preheater unit having a heater for heating an asphalt surface, scarifying rakes to scarify the heated surface and to release moisture contained in the asphalt, and a bin to dispense aggregate onto the heated and scarified asphalt surface;

supplying a recycling machine, said machine having 1. a heater for maintaining the temperature of the preheated asphalt and aggregate, 2. scarifying rakes for applying a second scarifying application to the heated asphalt and to premix said aggregate and loosened asphalt, 3. a plurality of extension mills for milling said surface to grade, applying a second pre-mixing application of the asphalt and aggregate, a second moisture release from the asphalt, 4. a main mill for milling said surface to grade, applying a third mixing application of the asphalt and aggregate, a third moisture release from the asphalt using negative pressure and 5. a mainframe;

adding a first application of rejuvenating fluid to the asphalt and aggregate at said main mill;

supplying a pug mill having first and second downwardly rotating rotors, said pug mill mixes the asphalt and liquid additives together to form a homogenous mix; and

at least one screed for laying the homogeneously mixed asphalt to grade.

2. The process of claim 1 wherein a second liquid additive is added at the pug mill.

3. The process of claim 1 wherein moisture is extracted by negative pressure at both the pug mill and main mill.

4. The process of claim 1 wherein a set of blades is attached to the machine'"'"'s scarifying rakes to loosen and collect asphalt located around obstructions.

5. The process of claim 1 wherein said aggregate dispensing bin is linked to a means for determining the width of the asphalt surface.

6. The process of claim 1 wherein said aggregate dispensing bin is linked to a means for determining the profile of the asphalt surface.

7. The process of claim 1 wherein said aggregate dispensing bin is linked to a means for determining the width and profile of the asphalt surface.

8. The process of claim 5 wherein said width determining means is comprised of two extendable arms.

9. The process of claim 6 wherein said profile measuring device is comprised of sonic sensors.

10. The process of claim 6 wherein said profile measuring device is comprised of mechanical sensors.

11. The process of claim 1 wherein the pug mill includes a blade for collecting material and to direct the material into the second pug mill rotor for mixing.

12. The process of claim 1 further including a ski, which exerts pressure on the material flow exiting the pug mill.

13. The process of claim 12 wherein said pressure exerted by said ski increases when there is a decrease in the drive pressure in said pug mill rotors and increases when there is in increase in the pressure of the pug mill rotors.

14. The process of claim 1 wherein said extension mills are comprised of a plurality of sections, each section being articuable about at least one pivot point.

15. The process of claim 1 wherein said extension mills are articulated by at least one hydraulic cylinder.

16. The process of claim 13 wherein said extension mills may be configured to create a grade that is crowned.

17. The process of claim 16 wherein said extension mills may be configured to create a grade that has a positive or negative crown.

18. The process of claim 1 wherein said bin includes a plurality of movable blades, said blades control the amount of material which is dispensed from said bin.

19. The process of claim 18 wherein the amount of material dispensed from said bin is controlled by varying the distance between the blades and a rotor located in said bin.

20. The process of claim 19 wherein said blades are adapted to permit the passage of over-sized objects by increasing the distance between the blades and rotor.

21. The process of claim 1 wherein either said preheater or said recycling machine includes a boom located on the side of the unit and an operated cab attached to the distal end of said boom.

22. The process of claim 1 wherein said heater of said recycling machine or preheater is comprised of a plurality of individually controlled electronic burners which are each connected to at least one temperature sensor which causes said burner to deactivate if a maximum temperatures is reached and reactivates when a minimum temperature is reached.

23. The process of claim 1 wherein said heater of said recycling machine or preheater includes a plurality of individually controlled electronic burners which are each connected to at least one flame sensor which causes said burner to deactivate when a flame is detected.

24. The process of claim 1 wherein said heater of said recycling machine or preheater includes a plurality of individually controlled electronic burners where each burner includes an air inlet passage which has a section with a reduced cross-sectional area to increase the velocity of air flow in said burner.

25. The process of claim 1 wherein said heater of said recycling machine or preheater includes a plurality of individually controlled electronic burners where each burner includes an air supply valve which restricts air flow so as to increase the fuel to air mixture in said burner.

26. The process of claim 1 wherein said heater of said recycling machine or preheater includes a plurality of individually controlled electronic burners where each burner includes a valve to modulate the gas flow to said burner.

27. The process of claim 1 wherein said heater of said recycling machine or preheater includes a plurality of individually controlled electronic burners which are programmed to operate with a predetermined number of active burners for normal operation and additional burners for providing additional heat when activated.

28. The process of claim 1 wherein said recycling machine includes a plurality of cross-linked skis for averaging changes in grade height to maintain a consistent grade height.

29. The process of claim 28 wherein said average grade height is used to adjust the position of said mills.

30. The process of claim 28 wherein said average grade height used to adjust the position of said mainframe.

31. The process of claim 1 wherein said recycling machine includes a plurality of longitudinally linked skis for averaging changes in grade height to maintain a consistent grade height.

32. The process of claim 1 wherein said recycling machine includes a plurality of longitudinally-linked contactless sensors for averaging changes in grade height to maintain a consistent grade height.

33. The process of claim 31 further including a dampening means in communication with said sensors for filtering out sudden grade changes.

34. The process of claim 1 further including a cross-slope produced by the mills.

35. The process of claim 1 wherein said recycling machines includes a surge bin having a plurality of discharge ports.

36. The process of claim 1 further including a divider, said divider positioned between said pug mill and said screed and rotatable about an axis whereby said divider is capable of directing the material flow into an auger which feeds said screed.

37. The process of claim 35 wherein said divider directs additional material into the area of said auger where there is a deficiency of material.

38. The process of claims 35 and 36 wherein said surge bin provides additional material into the area of said auger where there is a deficiency of material.

39. The process of claim 1 wherein said recycling machine includes a front axle and a rear axle, each of said axles having a passage way in which a conveyor extends.

40. The process of claim 39 wherein said conveyor extends upwardly through said front axle.

41. The process of claims 35 and 39 wherein said conveyor is in communication with said surge bin.

42. The process of claim 39 further including a detachable hopper in communication with said conveyor.

43. The process of claim 42 wherein said attachable hopper includes a 5^th wheel pin and is positionable in a raised and lowered position, in said raised position said 5^th wheel pin is capable of engaging a transport vehicle

44. The process of claim 1 wherein said recycling machine includes a first and second screed, said first screed positioned to create a mat of material on top of a mat of material created by said second screed.

45. The process of claim 43 wherein said first screed is a master and said second screed is a slave.

46. The process of claim 43 wherein a hydraulic means is used to maintain a constant spacial differential between said first and second screed.

47. The process of claim 43 wherein opposingly located tow points are used to position said screeds.

48. The process of claim 34 wherein said surge bin includes a vertical elevator.

49. The process of claim 47 wherein said vertical elevator is positionable into processed material so as to convey the material into said surge bin.

50. The process of claim 47 wherein said vertical elevator is adapted to communicate with said conveyor to add new asphalt to said surge bin.

51. The process of claim 47 wherein said vertical elevator is adapted to collect material from both said conveyor and said process material for storage in said surge bin.

52. The process of claim 34 wherein said surge bin has an opening for receiving asphalt from an external source.

53. An asphalt paving machine operable in both a paving and transportation mode comprising:

a mainframe having a plurality of attachment points;

a plurality of retractable wheels connected to and depending from said main frame;

said rear attachment points adapted to engage an attachable transportation frame having at least one axle and corresponding wheels;

a retractable stinger having a 5^th wheel pin connector;

in said transportation mode said stinger is in an extended position, said transportation frame is connected to said mainframe and said wheels are retracted; and

in said paving mode, said stinger is retracted and said wheels are extended.

54. The paving machine of claim 53 further including a safety latch for securing said transportation frame to said mainframe, said latch comprising opposingly located saddles sized to receive at least two of said attachment points, and a latch positionable between open and closed positions, in said open position said attachment points are insertable into said saddles and in said closed position at least one of said attachment point is retained within said saddle.

55. The paving machine of claim 53 wherein said transportation frame includes a plurality of axle and wheel sets, said axles positionable along said frame.

56. The paving machine of claim 53 further including a storage bin attachable to said attachment points.

57. The paving machine of claim 56 further including a safety latch for securing said bin to said mainframe, said latch comprising opposingly located saddles sized to receive said attachment points, and a latch positionable between open and closed positions, in said open position said attachment points are insertable into said saddles and in said closed position at least one of said attachment point is retained within said saddle.

58. The paving machine of claim 53 wherein said paving machine is a preheater.

59. The paving machine of claim 53 wherein said paving machine is a recycling machine.

60. The paving machine of claim 53 wherein said stinger is releasably attachable to a plurality of attachment points.

61. The paving machine of claim 60 further including a safety latch for securing said stinger to said mainframe, said latch comprising opposingly located saddles sized to receive at least two of said attachment points, and a latch positionable between open and closed positions, in said open position said attachment points are insertable into said saddles and in said closed position at least one of said attachment point is retained within said saddle.

62. The paving machine of claim 53 further including a storage bin, attachment points located on said storage bin.

63. An asphalt paving machine operable in both a paving and transportation mode comprising:

a mainframe having a plurality of attachment points;

a plurality of retractable wheels connected to and depending from said mainframe;

at least two of said attachment points adapted to engage an attachable transportation frame having at least one axle and corresponding wheels;

a storage bin including a 5^th wheel pin connector, said storage bin releasably attachable to at least two attachment points and positionable between raised and lowered positions;

in said transportation mode said bin is in said raised position, said transportation frame is connected to said main frame and said wheels are retracted; and

in said paving mode, said bin is in said lowered position and said wheels are extended.

64. The paving machine of claim 63 further including a safety latch for securing said transportation frame to said mainframe, said latch comprising opposingly located saddles sized to receive at least two of said attachment points, and a latch positionable between open and closed positions, in said open position said attachment points are removable and in said closed position at least one said attachment point is retained within said saddle.

65. The paving machine of claim 63 wherein said transportation frame includes a plurality of axle and wheel sets, said axles positionable along said frame.

66. The paving machine of claim 63 further including a safety latch for securing said bin to said mainframe, said latch comprising opposingly located saddles sized to receive at least two of said attachment points, and a latch positionable between open and closed positions, in said open position said attachment points are insertable into said saddles and in said closed position at least one of said attachment point is retained within said saddle.

67. The paving machine of claim 63 wherein said paving machine is a recycling machine.

68. The paving machine of claim 63 further including a second storage bin, attachment points located on said storage bin.