Pavement repair system

• US 9,637,870 B1
• Filed: 02/08/2017
• Issued: 05/02/2017
• 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:
  US15/428,088
• Publication Number:
  US 20170145640A1
• Time in Patent Office: 83 Days
• Field of Search: 404 75, 404 77, 404 79
• 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 utilizing 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. A method for providing an asphalt pavement with a new wearing surface, comprising:

spraying a rubberized asphalt emulsion onto a surface of an asphalt pavement;

broadcasting stone into the rubberized asphalt emulsion; and

irradiating the rubberized asphalt emulsion with stone and a surface layer of the asphalt pavement with radiation having a preselected peak wavelength of from 1 nm to 5 mm such that the rubberized asphalt emulsion hardens and bonds to the stone, whereby the asphalt pavement is provided with a new wearing surface wherein the preselected wavelength is selected based on at least one criterion selected from the group consisting of stone petrography of the aggregate, an asphaltene/maltene content of the asphalt emulsion and testing data conducted on representative samples.

2. The method of claim 1, wherein the peak wavelength of the radiation is selected such that the radiation penetrates through and heats the rubberized asphalt emulsion with stone and the surface layer of the asphalt pavement to a depth of at least two inches from a topmost pavement surface, wherein a temperature differential throughout a top two inches of the pavement is 100°

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

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

F.

3. The method of claim 1, wherein the peak wavelength of the radiation is selected based on at least one criterion selected from the group consisting of absorbed wavelength quanta data related to a stone petrography, an asphaltene/maltene content of the asphalt of the rubberized asphalt emulsion or the asphalt pavement, an average crack width by depth topography of the asphalt pavement, and exploratory testing conducted on representative portions of the surface of the asphalt pavement.

4. The method of claim 1, wherein the stone is from ¼

inch to ⅜

inch in diameter.

5. The method of claim 1, wherein the asphalt pavement is an old road base in need of repair, wherein the old road base is not disrupted.

6. The method of claim 1, wherein the preselected peak wavelength is from 1,000 nm to 10,000 nm.

7. The method of claim 1, wherein the preselected peak wavelength is from 1 nm to 10,000 nm.

8. The method of claim 7, further comprising irradiating the rubberized asphalt emulsion with stone and the surface layer of the asphalt pavement with a second radiation having a second preselected peak wavelength of from 1 mm to 5 mm.

9. The method of claim 1, further comprising subjecting the new wearing surface to compaction, whereby the irradiated rubberized asphalt emulsion with stone is fused to the irradiated surface layer of the asphalt pavement.

10. The method of claim 1, wherein the rubberized asphalt emulsion comprises an elastomer selected from the group consisting of a butyl rubber, a styrene-butadiene-styrene polymer, a styrene/acrylate copolymer, a chlorinated natural rubber, a thermoplastic, and a bioresin.

11. The method of claim 10, wherein the rubberized asphalt emulsion 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.

12. The method of claim 11, wherein the rubberized asphalt emulsion comprises at least one binder crosslink component selected from the group consisting of polyurethanes, isocyanates, bisphenol A-based liquid epoxy resins, and aliphatic glycol epoxy resins.

13. The method of claim 12, wherein the rubberized asphalt emulsion comprises 20% to 40% solids.

14. The method of claim 1, wherein the rubberized asphalt emulsion comprises butyl rubber, diene modified asphalt, and a triglyceride bioresin, wherein the rubberized asphalt emulsion contains no perfluorocarbons and no polyaromatic hydrocarbons as volatile components.

15. The method of claim 1, wherein the rubberized asphalt emulsion is a waterborne emulsion of a polymer modified asphalt.

16. The method of claim 1, wherein the stone is granite rock, and wherein the preselected peak wavelength is from 3,000 nm to 5,000 nm.

17. The method of claim 1, wherein the stone is limestone, and wherein the preselected peak wavelength is from 3,000 nm to 4,000 nm.

18. The method of claim 1, wherein the stone is sand, and wherein the preselected peak wavelength is from 5,000 nm to 8,000 nm.

19. The method of claim 1, wherein the radiation is generated by at least one emitter, wherein each emitter comprises an emitter panel comprising a birefringent material through which an electromagnetic radiation generated by the emitter passes, wherein the birefringent material exhibits biaxial birefringence.

20. The method of claim 1, wherein the broadcasting stone into the rubberized asphalt emulsion comprises broadcasting a binder coated stone into the rubberized asphalt emulsion.

21. The method of claim 1, wherein the rubberized asphalt emulsion with stone forms a layer having a thickness of approximately ½

inch.

22. The method of claim 1, further comprising subjecting the irradiated rubberized asphalt emulsion with stone to vibratory compaction.