Pavement repair system

• US 9,347,187 B2
• Filed: 05/01/2015
• Issued: 05/24/2016
• 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:
  US14/702,610
• Publication Number:
  US 20150233067A1
• Time in Patent Office: 389 Days
• Field of Search: 404/75, 404/77, 404/79, 404/95
• US Class Current: 1/1
• 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 19/002 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 23/00 Auxiliary devices or arrangements for constructing, repairing, reconditioning, or taking-up road or like surfaces apparatus for reconditioning of salvaged non-hydraulic compositions for- in plant recycling of salvaged bituminous mixtures E01C19/10
• 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 23/065 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 23/14 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 7/358 with a combination of two or more binders according to groups E01C7/351 - E01C7/356
• CPC Class Codes: H05B 3/0038 for industrial applications
• CPC Class Codes: H05B 6/48 Circuits

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, comprising:

a structural frame; and

one or more emitter panels situated within the structural frame, wherein the metal frame is insulated with a layer of a high-density ceramic, wherein each emitter panel comprises a serpentine wire positioned between the high-density ceramic and a sheet of a micaceous material exhibiting biaxial birefringence, wherein each emitter panels is configured such that, in use, energy generated by each emitter panel passes through the sheet of micaceous material.

2. The emitter system 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 system of claim 1, further comprising a power source configured to supply electrical power to the one or more emitter panels, wherein the power source is a portable generator.

4. The emitter system of claim 3, wherein the portable generator is a diesel generator configured to deliver at least 250 kW.

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

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

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

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

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

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

11. The emitter system of claim 1, wherein each emitter panel is configured to produce energy with a power density of from 3 to 15 W/in².

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

passing the emitter system of claim 1 over an asphalt pavement in need of repair, wherein the emitter system radiates terahertz energy into 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.

13. The method of claim 12, wherein the asphalt pavement is damaged asphalt pavement, the method further comprising, before passing an 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.

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

15. The method of claim 13, 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.

16. The method of claim 13, 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.

17. The method of claim 13, wherein a temperature differential throughout a top two inches of asphalt pavement is 100°

F. or less.

18. The method of claim 13, wherein the terahertz energy comprises wavelengths of from 1 nm to 5 mm.

19. The method of claim 13, wherein the terahertz energy comprises wavelengths of from 2 nm to 5 mm.

20. The method of claim 13, wherein the oligomers possess 2-150 repeating units.

21. The method of claim 13, further comprising, after passing the emitter system 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.