Roadway paving system and method including roadway paving vehicle and supply truck

• US 6,805,516 B2
• Filed: 06/04/2001
• Issued: 10/19/2004
• Est. Priority Date: 06/04/2001
• Status: Expired due to Term

• Current Assignee: ArrMaz Custom Chemicals, Inc., ED Etnyre & Company
• Original Assignee: ED Etnyre & Company, KMC Enterprises Inc. (Worth Corp)
• Inventors: Barnat, James J., Brown, Thomas R., OʼBrien, Patrick, Dabbs, Harold, Hannebaum, Tyrone, Heller, Jeremy
• Primary Examiner(s): Pezzuto, Robert E.
• Assistant Examiner(s): Addie, Raymond W
• Application Number:
  US09/873,800
• Publication Number:
  US 20020182009A1
• Time in Patent Office: 1,233 Days
• Field of Search: 404/101, 404/102, 404/108, 404/109, 404/111, 404/114, 404/118, 404/110, 141/231, 141/399, 137/312, 137/579, 414/502, 417/900
• US Class Current: 404/101
• CPC Class Codes: E01C 19/21 for simultaneously but separately applying liquid material and granular or pulverulent material, e.g. bitumen and grit, with or without spreading with rolling E01C19/4813; for filling grooves and gritting the filling
• 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 2019/2075 with longitudinal conveyor belt

Abstract

A roadway paving system for chipsealing a roadway surface comprising a novel roadway paving vehicle and a novel supply truck is provided. The roadway paving vehicle comprises an asphalt binder material dispensing system and an aggregate material dispensing system. The asphalt binder material dispensing system includes an asphalt tank and a sprayer that sprays a first layer of the asphalt binder material over the roadway surface. The aggregate material dispensing system comprises an aggregate hopper and conveyor mechanism that discharges a second layer of aggregate material over the roadway surface. No wheels run over a freshly laid surface. Supply trucks are linked to the roadway paving vehicle to refill the roadway paving vehicle on a continuous basis without the need of stopping the vehicle.

Claims

1. A roadway paving apparatus for applying asphalt binder material and aggregate material to a ground surface, comprising:

a vehicle having an engine and wheels, the vehicle having opposed front and rear ends;

an aggregate material dispensing system carried by the vehicle, comprising;

(a) an input hopper disposed proximate the front end of the vehicle adapted to receive aggregate material;

(b) an output hopper disposed proximate the rear end of the vehicle, the output hopper converging toward a discharge port adapted to discharge aggregate material over the ground surface;

(c) a conveyor mechanism extending between the input hopper and the output hopper, the conveyor mechanism adapted to transport aggregate material from the input hopper to the output hopper;

an asphalt binder material dispensing system carried by the vehicle separate from the aggregate material system such that asphalt binder material and aggregate material are not mixed prior to aggregate material being dispensed through the discharge port, the asphalt binder material dispensing system comprising;

(a) a tank for holding asphalt binder material;

(b) a spray bar between the discharge port and the front end, the spray bar having a plurality of nozzles adapted to spray asphalt binder material; and

(c) a pump mechanism adapted to pump asphalt binder material from the tank to the spray bar;

wherein all of the wheels roll on the ground surface between the spray bar and the front end such that no wheels roll over asphalt binder material and aggregate material that are discharged by the spray bar and through the output hopper; and

wherein the nozzles and the discharge port are arranged with substantially non-intersecting trajectories such that asphalt binder material and aggregate material ate substantially prevented from being mixed prior to contact with the ground surface during operation.

2. A roadway paving apparatus for applying asphalt binder material and aggregate material to a ground surface, comprising:

a vehicle having an engine and wheels, the vehicle having opposed front and rear ends;

an aggregate material dispensing system carried by the vehicle, comprising;

(a) an input hopper disposed proximate the front end of the vehicle adapted to receive aggregate material;

(b) an output hopper disposed proximate the rear end of the vehicle, the output hopper converging toward a discharge port adapted to discharge aggregate material over the ground surface;

(c) a conveyor mechanism extending between the input hopper and the output hopper, the conveyor mechanism adapted to transport aggregate material from the input hopper to the output hopper;

an asphalt binder material dispensing system carried by the vehicle separate from the aggregate material system such that asphalt binder material and aggregate material are not mixed prior to aggregate material being dispensed through the discharge port, the asphalt binder material dispensing system comprising;

(a) a tank for holding asphalt binder material;

(b) a spray bar between the discharge port and the front end, the spray bar having a plurality of nozzles adapted to spray asphalt binder material; and

(c) a pump mechanism adapted to pump asphalt binder material from the tank to the spray bar;

wherein all of the wheels roll on the ground surface between the spray bar and the front end such that no wheels roll over asphalt binder material and aggregate material that are discharged by the spray bar and through the output hopper; and

wherein all of the nozzles for spraying asphalt binder material are arranged in front of the discharge port and such that asphalt binder material is not sprayed behind the discharged aggregate material during operation.

3. The roadway paving apparatus of claim 2 further comprising:

an input conduit proximate the input hopper terminating in a hydraulic coupling, the hydraulic coupling adapted to connect to a supply of asphalt binder material; and

an input asphalt pump connecting the input conduit to the tank for pumping asphalt binder material into the tank.

4. The roadway paving apparatus of claim 3 wherein the pump mechanism comprises an output asphalt pump interposed between the tank and the spray bar.

5. The roadway paving apparatus of claim 4 further comprising a swivel joint in the input conduit allowing rotation of the hydraulic coupling.

6. The roadway paving apparatus of claim 2 further comprising a mechanical coupling at the front end of the vehicle, the mechanical coupling adapted to selectively attach and detach from a supply truck carrying aggregate material for filling the input hopper.

7. The roadway paving apparatus of claim 2 further comprising at least one auger in the input hopper extending horizontally at locations above a front portion of the conveyor mechanism proximate the front end, the at least one auger arranged to spread out aggregate material received from the supply truck to increase effective holding capacity of the input hopper.

8. The roadway paving apparatus of claim 7 wherein the input hopper includes expansion wings at opposed sides of the input hopper for increasing holding capacity of the input hopper, the expansion wings pivoting from a lowered position wherein a first horizontal spacing is defined between the expansion wings to a raised transport position wherein a second horizontal spacing is defined between the expansion wings that is less than the first horizontal spacing sufficient to allow transportation within a single lane of a roadway.

9. The roadway paving apparatus of claim 2 further comprising:

a plurality of control valves mounted to the spray bar, each control valve controlling flow of asphalt binder material to at least one of the nozzles, the control valves having open and closed states for allowing and preventing flow of asphalt binder material to individual nozzles.

10. The roadway paving apparatus of claim 9 further comprising:

a plurality of gates dividing the discharge port into a plurality of sections, the gates having open and closed states for allowing and preventing discharge of aggregate material; and

further comprising;

a controller controlling the opening and closing of the control valves and the gates setting an application width for asphalt binder material and aggregate material.

11. The roadway paving apparatus of claim 2, wherein the conveyor mechanism comprises first and second endless belt conveyors, and wherein the output hopper comprises first and second dispensing bins, first and second endless belt conveyors extending diagonally and vertically upward from the front end toward the rear end outputting aggregate material into the first and second bins, the bins being horizontally movable expanding and contracting the discharge port between minimum and maximum application widths for the discharge port.

12. The roadway paving apparatus of claim 11 further comprising extendible and retractable arms on the spray bar extending the spray bar substantially equivalent to the maximum application width.

13. The roadway paving apparatus of claim 2 wherein the spray bar is generally parallel to the discharge port and spaced in front of the discharge port between about 0.1 and about 10 feet.

14. The roadway paving apparatus of claim 2 wherein the roadway paving apparatus applies asphalt binder material and aggregate material at a maximum speed of between about 1 and about 15 miles per hour.

15. The roadway paving apparatus of claim 2 wherein the roadway paving apparatus is free of spreading apparatus behind the discharge port.

16. The roadway paving apparatus of claim 2, wherein the output hopper is a part of the vehicle, wherein the roadway paving apparatus is free of aggregate dispensing trailers.

17. The roadway paving apparatus of claim 2, wherein the vehicle and anything carried thereby is free of any apparatus that would contact the ground surface behind the discharge port.

18. The roadway paving apparatus of claim 2, wherein aggregate material is transported from the input hopper to the output hopper for discharge via only one conveyor of the conveyor mechanism.

19. A method of chipsealing a roadway surface with a roadway paving vehicle, the roadway paving vehicle comprising a front end and a rear end, the method comprising:

storing a supply of asphalt binder material in a tank on the roadway paving vehicle;

transporting asphalt binder material from the tank to a spray bar at the rear end of the roadway paving vehicle;

spraying asphalt binder material from the spray bar at a first span over the roadway surface forming a layer of asphalt binder material on the roadway surface;

storing a supply of aggregate material in an input hopper at the front end of the roadway paving vehicle;

transporting aggregate material from the input hopper to an output hopper at the rear end of the roadway paving vehicle;

discharging aggregate material from the output hopper at a second span over the layer of asphalt binder material; and

substantially preventing intermixing of asphalt binder material and aggregate material prior to the discharging of aggregate material and spraying of asphalt binder material and prior to contact of the aggregate material with the roadway surface.

20. The method of claim 19 further comprising:

providing a supply truck;

linking the front end of the roadway paving vehicle with the supply truck simultaneously while the roadway paving vehicle is moving forward, spraying asphalt binder material and discharging aggregate material, wherein the supply truck and the roadway paving vehicle travel forward in unison after being linked, the supply truck including a supply tank of asphalt binder material and an elongate supply hopper of aggregate material; and

refilling the tank with asphalt binder material and the input hopper with aggregate material wherein refilling is completed without stopping the roadway paving vehicle.

21. The method of claim 20 further comprising:

mobilizing aggregate material from the supply truck to refill the input hopper of the roadway paving vehicle via a live bottom conveyor on the supply truck; and

controlling the live bottom conveyor via a control module at an operator station on the roadway paving vehicle to selectively control refilling of the input hopper.

22. The method of claim 21 wherein supply truck includes a tailgate, further comprising:

extending the control module from the supply truck to the operator station by opening the tailgate, the control module being supported by the tailgate.

23. The method of claim 22 wherein the supply truck includes a tailgate controlling discharge of aggregate material into the input hopper, further comprising:

extending a transfer conduit from the supply truck to an operator station on the roadway paving vehicle; and

hooking the transfer conduit into a input conduit at the operator station to transfer asphalt binder material into the tank.

24. The method of claim 23 further comprising pumping asphalt binder material into the tank via an input pump mounted on the roadway paving vehicle.

25. The method of claim 19 further comprising:

selectively controlling valves on the spray bar to vary the first span and set a selected length of the first span; and

selectively controlling gates on the output hopper to vary the second span and set a selected length of the second span.

26. The method of claim 23 further comprising:

varying the lengths of the first and second spans in substantial unison such that substantially all asphalt binder material is covered with aggregate material.

27. The method of claim 19 further comprising:

supporting the entire roadway vehicle with wheels disposed entirely in front of the spraying of asphalt binder material and discharging of aggregate material such that no wheels roll over sprayed asphalt binder material or discharged aggregate material.

28. The method of claim 19 wherein the discharging of aggregate material and the spraying of asphalt binder material are spaced between about 0.1 and about 10 feet.

29. The method of claim 19 wherein the roadway paving apparatus sprays asphalt binder material and discharges aggregate material at a maximum speed of between about 1 and about 15 miles per hour.

30. The method of claim 19, wherein the discharging of aggregate is conducted behind all of the spraying of asphalt binder material such that asphalt binder material is not sprayed behind the discharging of aggregate material.

31. The method of claim 19, further comprising:

refilling the supply of aggregate material and refilling the supply of asphalt binder material, while simultaneously continuing to spray asphalt material and discharge aggregate material during a continuous chipsealing operational mode; and

preventing stoppage of the spraying and discharge material for refilling and thereby preventing the formation of roadway bumps when the supplies are refilled.

32. A method of chipsealing a roadway surface using a roadway paving vehicle having wheels, comprising:

spraying asphalt binder material from the roadway paving vehicle over a roadway surface forming a layer of asphalt binder material on the roadway surface;

discharging aggregate material from the roadway paving vehicle over the layer of asphalt binder material;

substantially preventing intermixing of asphalt binder material and aggregate material prior to the application of aggregate material and spraying of asphalt binder material to the roadway surface and prior to contact of the aggregate material and spraying of asphalt binder material with the roadway surface; and

insuring that no wheels of the roadway paving vehicle roll over the asphalt binder material or aggregate material after they are discharged onto the roadway.

33. The method of claim 32 further comprising:

linking the roadway paving vehicle with a supply truck while continuing the spraying of asphalt binder material and discharging aggregate material with the supply truck and the roadway paving vehicle traveling forward in unison, the supply truck including a supply of asphalt binder material and a supply of aggregate material; and

transferring the supply of asphalt binder material and the supply of aggregate material from the supply truck to the roadway paving vehicle.

34. The method of claim 33 further comprising

controlling the transferring of the supply of asphalt binder material and the supply of aggregate material to the roadway paving vehicle at an operator station on the roadway paving vehicle.

35. The method of claim 33 further comprising:

unlinking the roadway paving vehicle and a supply truck while continuing the spraying of asphalt binder material and discharging aggregate material; and

linking the roadway paving vehicle with a second supply truck while continuing the spraying of asphalt binder material and discharging aggregate material with the second supply truck and the roadway paving vehicle traveling forward in unison, the second supply truck including a supply of asphalt binder material and a supply of aggregate material; and

transferring the supply of asphalt binder material and the supply of aggregate material from the second supply truck to the roadway paving vehicle.

36. The method of claim 32 further comprising:

selectively controlling the spraying to set a first span of a first length over which asphalt binder material is sprayed; and

selectively controlling the discharging to set a second span of a second length over which aggregate material is discharged.

37. The method of claim 36 further comprising:

varying the lengths of the first and second spans in substantial unison such that substantially all asphalt binder material is covered with aggregate material.

38. The method of claim 32 further comprising:

supporting the entire roadway paving vehicle with wheels disposed entirely in front of the spraying of asphalt binder material and discharging of aggregate material such that no wheels roll over sprayed asphalt binder material or discharged aggregate material.

39. The method of claim 32 wherein the discharging of aggregate material and the spraying of asphalt binder material are spaced between about 0.1 and about 10 feet.

40. The method of claim 32 wherein the roadway paving apparatus sprays asphalt binder material and discharges aggregate material at a maximum speed of between about 1 and about 15 miles per hour.

41. A roadway paving system for chipsealing a roadway surface, comprising:

a roadway paving vehicle comprising an asphalt binder material dispensing system and an aggregate material dispensing system, the asphalt binder material dispensing system including an asphalt tank containing a first supply of asphalt binder material and a sprayer spraying asphalt binder material over the roadway surface, the aggregate material dispensing system holding a first supply of aggregate material and discharging aggregate material over the roadway surface over the first layer;

at least two supply trucks, each supply truck comprising a supply hopper containing a second supply of aggregate material and supply tank containing a second supply of asphalt binder material;

a link between a first one of the supply trucks and the roadway paving vehicle including a transfer conduit transferring asphalt binder material from the supply tank to the asphalt tank, and wherein aggregate material is transferred from the supply hopper to the aggregate dispensing system;

wherein the asphalt tank and aggregate material dispensing system have a sufficient holding capacity such that said first one of the supply trucks may be unlinked from the roadway paving vehicle and a second one of the supply trucks may be linked to the roadway paving vehicle with continuous application of asphalt binder material and aggregate material without stopping the roadway paving vehicle; and

wherein the supply truck includes a tailgate closing a discharge region of the supply hopper, the tailgate moving toward the roadway paving vehicle to open the discharge region to allow discharge of aggregate material from a rear end of the supply truck, the transfer conduit being carried by the tailgate and connected to the supply tank, the transfer conduit and hydraulic coupling extending with the tailgate for connection when the tailgate moves towards the roadway paving vehicle.

42. The roadway paving system of claim 41, wherein the aggregate material dispensing system includes an input hopper disposed proximate a front end of the vehicle adapted to receive aggregate material and an output hopper disposed proximate a rear end of the vehicle, the output hopper converging toward a discharge port discharging aggregate material over the roadway surface, the aggregate dispensing system further comprising a conveyor mechanism extending between the input hopper and the output hopper, the conveyor transporting aggregate material from the input hopper to the output hopper.

43. The roadway paving system of claim 41, wherein the sprayer comprises a spray bar, a plurality of nozzles spraying asphalt binder material, and a pump for pumping asphalt binder material from the asphalt tank to the spray bar.

44. The roadway paving system of claim 41, wherein the roadway paving vehicle includes a plurality wheels for support, all of the wheels being arranged such that no wheels roll over asphalt binder material and aggregate material that have been applied to the roadway surface.

45. The roadway paving system of claim 41 wherein the roadway paving vehicle further comprises:

an operator station adapted to support an operator; and

an input conduit fluidically connected to the transfer conduit through a detachable hydraulic coupling at the operator station.

46. The roadway paving system of claim 45 wherein the input conduit comprises a swivel joint allowing rotation of hydraulic coupling.

47. The roadway paving system of claim 41 wherein the spraying of asphalt binder material and the discharging of aggregate material are spaced horizontally between about 0.1 and about 10 feet.

48. The roadway paving system of claim 41 wherein the roadway paving apparatus applies the first and second layers of asphalt binder material and aggregate material at a maximum speed of between about 1 and about 15 miles per hour.

49. The roadway paving system of claim 42 wherein the supply truck comprises a conveyor mechanism in the supply hopper adapted to convey aggregate material into the input hopper of the roadway paving vehicle, and further comprising a control module adapted to be operated at a location on the roadway paving vehicle for use by an operator on the roadway paving vehicle, the control module controlling the conveyor mechanism.

50. The roadway paving system of claim 41 further comprising a support arm mounted to the tailgate, the support arm supporting the transfer conduit.

51. The roadway paving system of claim 50 wherein the supply truck comprises a conveyor mechanism in the supply hopper adapted to convey aggregate material into aggregate hopper, further comprising a control module supported by the support arm and electronically connected to the conveyor mechanism, the control module controlling operation of the conveyor mechanism to control discharge of material from the hopper.

52. The roadway paving system of claim 50 wherein the tailgate comprises a pair of doors, the doors being pivotably mounted to the hopper such that the doors pivot horizontally outwardly away from each other to open the discharge region and inwardly toward each other to close the discharge region, the support arm being mounted to one of the doors.

53. A roadway paving apparatus for applying asphalt binder material and aggregate material to a ground surface, comprising:

a vehicle having an engine and wheels, the vehicle having opposed front and rear ends;

an aggregate material dispensing system carried by the vehicle adapted to hold a supply of aggregate material and having a discharge port proximate the rear end of the vehicle behind the wheels, the discharge port adapted to discharge aggregate material over the ground surface, the aggregate material dispensing system including a conveyor mechanism extending substantially between the front and rear ends for transporting aggregate material rearwardly toward the discharge port;

an asphalt binder material dispensing system carried by the vehicle separate from the aggregate material system such that asphalt binder material and aggregate material are not mixed prior to aggregate material being dispensed through the discharge port, the asphalt binder material dispensing system adapted to hold a supply of asphalt binder material, the asphalt binder material dispensing system including a sprayer having a spray bar with a plurality of nozzles, the spray bar adapted to spray asphalt binder material through the nozzles behind the wheels;

wherein all of the wheels roll on the ground surface between the spray bar and the front end such that no wheels roll over asphalt binder material and aggregate material that are discharged by the spray bar and through the discharge port; and

wherein the nozzles and the discharge port are arranged with substantially non-intersecting trajectories such that during operation the asphalt binder material and aggregate material are substantially prevented from being mixed prior to contact with the around surface.

54. The roadway paving apparatus of claim 53 wherein the aggregate material dispensing system further comprises an input hopper disposed proximate the front end of the vehicle adapted to receive aggregate material and an output hopper disposed proximate the rear end of the vehicle, the output hopper converging toward the discharge port.

55. The roadway paving apparatus of claim 53 wherein the asphalt binder material dispensing system further comprises a tank for holding asphalt binder material and a pump mechanism adapted to pump asphalt binder material from the tank to the spray bar.

56. The roadway paving apparatus of claim 55 further comprising:

an input conduit proximate the input hopper terminating in a hydraulic coupling, the hydraulic coupling adapted to connect to a supply of asphalt binder material; and

an input asphalt pump connecting the input conduit to the tank for pumping asphalt binder material into the tank.

57. The roadway paving apparatus of claim 55 wherein the pump mechanism comprises an output asphalt pump interposed between the tank and the spray bar.

58. The roadway paving apparatus of claim 53 further comprising a mechanical coupling at the front end of the vehicle, the mechanical coupling adapted to selectively attach and detach from a supply truck carrying aggregate material for filling the input hopper.

59. The roadway paving apparatus of claim 54 further comprising at least one auger in the input hopper extending horizontally at locations above a front portion of the conveyor mechanism proximate the front end, the at least one auger arranged to spread out aggregate material received from the supply truck to increase effective holding capacity of the input hopper.

60. The roadway paving apparatus of claim 59 wherein the input hopper includes expansion wings at opposed sides of the input hopper for increasing holding capacity of the input hopper, the expansion wings pivoting from a lowered position wherein a first horizontal spacing is defined between the expansion wings to a raised transport position wherein a second horizontal spacing is defined between the expansion wings that is less than the first horizontal spacing sufficient to allow transportation within a single lane of a roadway.

61. The roadway paving apparatus of claim 53 further comprising:

a plurality of control valves mounted to the spray bar, each control valve controlling flow of asphalt binder material to at least one of the nozzles, the control valves having open and closed states for allowing and preventing flow of asphalt binder material to individual nozzles.

62. The roadway paving apparatus of claim 61 further comprising:

a plurality of gates dividing the discharge port into a plurality of sections, the gates having open and closed states for allowing and preventing discharge of aggregate material; and

further comprising;

a controller controlling the opening and closing of the control valves and the gates setting an application width for asphalt binder material and aggregate material.

63. The roadway paving apparatus of claim 53 wherein the roadway paving apparatus is free of spreading apparatus behind the discharge port.

64. The roadway paving apparatus of claim 53, wherein all of the nozzles for spraying asphalt binder material are arranged in front of the discharge port such that asphalt binder material is not sprayed behind the discharged aggregate material during operation.

65. The roadway paving apparatus of claim 53, further comprising means including a hydraulic coupling adapted to attach and detach with an external asphalt binder supply for enabling a continuous application mode wherein aggregate and asphalt binder material are continuously dispensed while the vehicle is moving and while the aggregate material dispensing system and the asphalt binder material system are being externally refilled.

66. A method of chipsealing a roadway surface using a roadway paving vehicle having wheels, comprising:

spraying asphalt binder material from the roadway paving vehicle over a roadway surface forming a layer of asphalt binder material on the roadway surface;

discharging aggregate material from the roadway paving vehicle over the layer of asphalt binder material;

keeping substantially all of the spraying of asphalt binder material in front of the discharging of aggregate material such that asphalt binder material is not sprayed behind the aggregate material;

preventing intermixing of asphalt binder material and aggregate material prior to the discharge of aggregate material and spraying of asphalt binder material to the roadway surface and prior to contact of the aggregate material and spraying of asphalt binder material with the roadway surface; and

insuring that no wheels of the roadway paving vehicle roll over the asphalt binder material or aggregate material after they are discharged onto the roadway.