Note: Descriptions are shown in the official language in which they were submitted.
CA 02859339 2016-10-18
Attorney Docket No. 29484-32
Integrated Asphalt Heating Unit and Comb
CROSS REFERENCE TO RELATED APPLICATION(S)
[001] This application relates to United States Patent Application Serial
No.: 13/932,702,
filed July 1, 2013, which is a Continuation of United States Patent
Application Serial No.:
13/587,485, now United States Patent No. 8,491,220.
BACKGROUND OF THE INVENTION
1. Field of the Invention.
[002] This disclosure is related to the field of devices for repairing
asphalt deterioration.
Specifically, this disclosure is related to raking tools utilized in the
asphalt infrared repair
process for the repair of potholes, raveled areas, utility cuts, and alligator
cracks, amongst
other instances of asphalt concrete degradation.
2. Description of Related Art.
[003] Asphalt concrete plays a huge role in the infrastructure of modern
day westernized
society. From its presence in roads, parking lots, driveways, airport landing
strips, and
taxiways, asphalt pavement is an integral component in transit infrastructure.
[004] Generally, in the art of asphalt paving, a road, parking lot,
driveway or airport
landing strip will be paved with an asphalt concrete with certain performance
characteristics
in terms of surface durability, tire wear, breaking efficiency, and roadway
noise for the
particular road and the type and degree of traffic the road is expected to
bear. However, over
time, environmental factors and traffic loads can cause asphalt concrete to
deteriorate. Often,
both environmental factors and traffic loads contribute to asphalt
deterioration and
degradation. Environmental factors which cause deterioration include heat and
cold, the
presence of water in the subbase or subgrade soil underlying the pavement, and
frost heaves,
1
CA 02859339 2014-08-14
,
Attorney Docket No. 29484-32
among other environmental factors. Traffic damage generally results from
trucks and buses,
and the damage caused is generally proportional to axle load raised by a
certain degree. The
deterioration and degradation caused by these factors includes, but is not
limited to, crocodile
cracking, potholes, upheaval, raveling, rutting, shoving, stripping, and grade
depressions,
amongst others.
[005] Irrespective of the causing agent, deterioration in asphalt roadways,
parking lots,
and other surfaces is a major problem. The deterioration can cause damage to
cars and
vehicles, decrease transit efficiency, and create an unsightly roadway and
parking lot
infrastructure, among other problems. To avoid these problems, roadways,
parking lots, and
other asphalt surfaces are regularly maintained to prevent and repair the
degradation and
deterioration of the asphalt surface that occurs over time.
[006] One method commonly used in the art of asphalt paving to repair
damage and
degradation is known as infrared repair. The infrared repair process is
capable of repairing
potholes, raveled areas, utility cuts, alligator cracks, bumps and low spots,
and drainage
problems, along with many of the other deterioration problems commonly
associated with
asphalt pavement. The infrared process is generally preferred in the art of
asphalt repair due
to its low cost and ability to create a seamless repair by thermally bonding
the edges of the
repair area with the existing asphalt.
[007] The infrared process generally takes place as follows. First, an
infrared panel is
placed over the area of the asphalt surface to be prepared. The panel is
maintained over the
repair area until the asphalt reaches a workable hot mix temperature,
generally around 280 -
300 F. The time required to reach this temperature will vary depending on the
ambient
temperature of the air and the asphalt pavement. The infrared rays which are
utilized are
desirable for their ability to heat the asphalt pavement without causing
burning or oxidation.
Once the repair area is heated to the desired working temperature, the repair
area is raked to
2
CA 02859339 2014-08-14
,
Attorney Docket No. 29484-32
agitate the top of the asphalt as deep as they can, generally 1" to 1.5" of
the asphalt, to scarify
(i.e., make cuts or scratches in) the remaining asphalt, and to add new
surface asphalt to the
repair area. After the addition of the new surface asphalt to the repair area,
the material is
blended together and luted for proper elevation. After the blending and
luting, the repair area
is compacted with a compacting tool known to those of ordinary skill in the
art such as a
vibratory compactor, which compacts the edges of the repair area to the
existing asphalt
surface, thus creating a thermal bond with the existing pavement and
eliminating any seams.
To complete the process, the area is allowed to cool before it receives any
traffic.
[008] Notably, a seamless repair is possible through the infrared process
because the
entirety of the heated repair area becomes workable again. Stated differently,
the heated
asphalt and asphaltic cement that holds the rocks together becomes workable
again. The new
asphalt that is added to the heated area is generally highly concentrated in
asphalt cement (the
glue that binds the rock particles together) so that it can be redistributed
throughout the repair
area. When the repair area is compacted, the repaired area is thermally bonded
or glued to
the older portion of the asphalt pavement, creating a patch that is flush with
the original
asphalt pavement. Further, this process is significantly better for the
environment than
simply tearing out the section and replacing it as less new asphalt is needed,
and there is less
transportation cost for getting the asphalt to and from the worksite.
[009] While the infrared repair process has many benefits over the other
processes
known to those of ordinary skill in the art for repairing asphalt, including
its ability to create a
seamless repair, the process as it is currently practiced in the art is latent
with inefficiencies
generally surrounding the manual raking process. For example, as noted
previously, in the
infrared process of the prior art, once the repair area reaches a desired
temperature after the
application of infrared heat, the repair area is raked manually by a laborer.
An example of an
asphalt rake that is commonly used for this process is provided in Prior Art
FIG. 1. Thus, in
3
CA 02859339 2014-08-14
=
,
Attorney Docket No. 29484-32
this step of the traditional infrared repair process, a laborer is required to
stand over or around
the heated asphalt patch and physically rake and move the hot asphalt to
remove the top layer
and agitate or scarify the remaining hot asphalt in the repair area.
Inherently, this process is
both labor intensive and time consuming. Often, the laborer must make multiple
raked passes
to sufficiently agitate and scarify the asphalt. In addition, after the
agitation, a laborer needs
to physically shovel the new heated asphalt mix into a wheelbarrow, transport
it to the repair
area, and rake and distribute it into the repair area. Both of these processes
are physically
exhaustive and extremely labor intensive due to the heat, fumes, and the
exertion needed to
perform both jobs. The problems can be further exacerbated by certain types of
asphalt
repairs. For example, the infrared heating can often not penetrate a boundary
between two
different asphalt lays, for example, as occurs in resurfacing. Thus, it can be
necessary to
agitate the entirety of the first level, and then work through that already
agitated material, or
completely remove it, to agitate the second.
[010] Because these processes are labor¨intensive jobs that require a
great amount of
physical strength and stamina, laborers often become fatigued as a day
progresses and the
quality, depth, and efficiency of their raking becomes compromised. Further,
manual raking
of the repair area by a laborer with an asphalt rake can be ineffective.
Laborers can only
apply a finite amount of down pressure on a hand rake. In addition, this
pressure can vary
across different points in the job and at different points in the day as a
laborer becomes more
fatigued. This varying amount of pressure applied to the rake generally
results in portions of
the repair area that are not raked to a required depth, resulting in the
reemerging of cracks
that will shorten the life of the repair. Generally, deeper raking is
desirable and creates a
better repair because it results in the removal of additional deep set cracks
prior to the time
the new asphalt mixture is introduced into the repair area. Thus, deeper
raking generally
results in a superior repair that will last longer.
4
CA 02859339 2014-08-14
,
Attorney Docket No. 29484-32
[011]
Another limitation beyond a given laborer's varying strength throughout the
day is
the strength of the rake. It is not uncommon for an application of too much
downward
pressure on the rake to result in the rake breaking, which not only could
temporarily comprise
the repair but could also be potentially harmful to the worker. Moreover, in
the traditional
labor-intensive infrared process, if a cold spot is encountered in the repair
area, it cannot be
raked. Rather, the patch must be reheated, which requires more time and fuel,
or the cold
spot can simply be ignored, which often results in an inadequate repair.
[012] Accordingly, there is a need in the art of asphalt repair for a device
that will eliminate
the inefficiencies and variability in quality inherent to the manual raking
components of the
infrared repair process.
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
SUMMARY OF THE INVENTION
[013] Because of these and other problems in the art, there is described
herein, among
other things, a mechanized asphalt comb device and method of mechanized
asphalt raking
that provides a reliable, easy-to-use, and efficient alternative to the
traditional manual raking
methodologies.
[014] There is described herein, among other things, an integrated asphalt
heating and
comb unit, the unit comprising: a heating pan, said pan providing heat from a
downward side
of said pan; and a plurality of teeth extending from said downward side in a
downward
orientation; wherein said integrated asphalt heating and comb unit is attached
to an
engineering vehicle such that said engineering vehicle can control and
manipulate said
integrated unit into a raised inactive position and a lowered active position;
and wherein,
when in said lowered active position, said integrated asphalt heating and comb
unit applies a
fixed downward pressure and depth of penetration to a surface.
[015] In an embodiment of the unit, said teeth are attached to a frame
surrounding said
heating pan.
[016] In an embodiment of the unit, said teeth are attached to a floating
frame moveable
relative to said pan and said floating frame is arranged below said downward
side of said pan.
[017] In an embodiment of the unit, at least one of said plurality of teeth
is removable
from said unit.
[018] In an embodiment, the unit further comprises: a wing support
extending from said
heating pan.
[019] In an embodiment of the unit, said wing support supports a propane
cylinder which
provides energy for at least part of said heat.
6
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
[020] In an embodiment of the unit, said wing support supports a battery
which provides
energy for at least part of said heat.
[021] In such an embodiment of the unit, said wing support comprised of a
propane
cylinder which provides energy for at least part of said heat.
[022] In an embodiment, the unit further comprises at least two wing
supports.
[023] In an embodiment, the unit further comprises a rail connecting said
at least two
wing supports.
[024] In an embodiment of the unit, said rail includes a control panel.
[025] In an embodiment of the unit, said rail includes a hydraulic motor.
[026] In an embodiment, the unit further comprises a hydraulic motor.
[027] In an embodiment, the unit further comprises a control panel.
[028] In an embodiment of the unit, when said integrated asphalt heating
and comb unit
is used to heat asphalt, said integrated unit is in a position between said
raised inactive
position and said lowered active position.
[029] There is also described herein, in an embodiment, a mechanized method
for
removing and applying asphalt during an asphalt repair, the method comprising:
obtaining an
integrated heating and comb unit, said unit comprising: a heating pan, said
pan providing heat
from a first side of said pan; and a plurality of teeth extending from said
first side in a
downward orientation; attaching said unit to an engineering vehicle such that
said
engineering vehicle can control and manipulate said unit into a raised
position, a lowered
position, and an intermediate position between said raised position and said
lowered position;
moving said engineering vehicle to an asphalt repair site with said unit in
said raised position;
positioning said unit in said intermediate position; utilizing said heating
pan to heat asphalt in
said asphalt repair site with said unit in said intermediate position; without
moving said
engineering vehicle, positioning said unit in said lowered position where said
teeth apply a
7
CA 02859339 2014-08-14
= ' "
Attorney Docket No. 29484-32
fixed downward pressure and depth of penetration to a surface; and scarifying
said asphalt in
said asphalt repair site with said teeth while said unit is in said lowered
position.
[030] In an embodiment, the method further comprises: not moving said
engineering
vehicle while scarifying said asphalt in said asphalt repair site.
[031] In an embodiment, the method further comprises: moving said
engineering vehicle
to scarify said asphalt in said asphalt repair site.
[032] In an embodiment, the method further comprises: prior to said heating
being
completed, positioning said unit in an additional position where said teeth
apply a fixed
downward pressure to said surface; and scarifying said surface.
[033] There is also described herein, in an embodiment, a mechanized method
for
removing and applying asphalt during an asphalt repair, the method comprising:
obtaining an
integrated heating and comb unit, said unit comprising: a heating pan, said
pan providing heat
from a first side of said pan; and a plurality of teeth extending from said
first side in a
downward orientation; attaching said unit to an engineering vehicle such that
said
engineering vehicle can control and manipulate said unit into a raised
position, and a lowered
position; moving said engineering vehicle to an asphalt repair site with said
unit in said raised
position; positioning said unit in said lowered position where said teeth
apply a fixed
downward pressure and depth of penetration to a surface; utilizing said
infrared heating panel
to heat asphalt in said asphalt repair site with said unit in said lowered
position; and
scarifying said asphalt in said asphalt repair site with said teeth while said
unit is in said
lowered position.
8
CA 02859339 2014-08-14
,
Attorney Docket No. 29484-32
BRIEF DESCRIPTION OF THE DRAWINGS
[034] FIG. 1 provides a perspective view of a prior art asphalt rake
utilized in the
traditional manual raking steps of infrared asphalt repair in the processes of
the prior art.
[035] FIG. 2 provides a side perspective view of an embodiment of an
asphalt comb in
the active down position.
[036] FIG. 3 provides another side perspective view of an embodiment of an
asphalt
comb in the active down position.
[037] FIG. 4 provides yet another side perspective view of an embodiment of
an asphalt
comb in the active down position.
[038] FIG. 5 provides a front perspective view of an embodiment of an
asphalt comb.
[039] FIG. 6 provides a side perspective view of an embodiment of an
asphalt comb in
the inactive raised position.
[040] FIG. 7 provides a perspective view of an embodiment of an asphalt
comb in a
loading position next to a hot asphalt mix storage container.
[041] FIG. 8 provides a perspective view of an embodiment of an asphalt
comb in a
dumping position over an asphalt repair area.
[042] FIG. 9 provides an underside view of an embodiment of an asphalt comb
integrated
into a heating pad.
[043] FIG. 10 provides an underside view of another embodiment of an
asphalt comb
integrated into a heating pad.
[044] FIG. 11 provides a front view of a skid steer mounting an embodiment
of an
integrated heating pad and asphalt comb unit that utilizes the embodiment of
the asphalt
comb of FIG. 9.
[045] FIG. 12 provides a side view of the embodiment of FIG. 11.
9
CA 02859339 2014-08-14
,
Attorney Docket No. 29484-32
[046] FIG. 13 provides a top view of the embodiment of FIG. 11 with the
tines position
shown.
[047] FIG. 14 provides the top view of FIG. 13 utilizing the asphalt comb
of FIG. 10.
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[048] FIGS. 2-5 provide various prospective views of an embodiment of the
mechanized
asphalt comb (101). As seen in FIGS 2-5, the mechanized asphalt comb (101) is
generally
comprised of a rake attachment (102). Generally, the rake attachment (102), as
most clearly
depicted in FIG. 4, will be comprised of a plurality of teeth or tines (103)
attached to and
dispersed along a horizontally aligned rake spine (104) in a downward
orientation. The
plurality of teeth or tines (103) on the rake attachment (102) may be spaced
equidistantly
from each other, as depicted in FIG. 4, or, in alternative embodiments, may be
spaced in a
random manner along the rake spine (104). As the term is utilized herein,
"rake attachment"
shall mean a horizontally aligned rake spine (104) with a plurality of teeth
or tines (103)
attached thereto in a downward orientation, as depicted in FIG. 4.
[049] The material that comprises the rake attachment (102) is not
determinative. Any
material known to those of ordinary skill in the art that can withstand the
impact of raking
and the heat of the asphalt in the infrared repair process is contemplated.
Contemplated
materials include, but are not limited to, steel, iron, hardened steel, and
other heavy duty
metals known to those of ordinary skill in the art. In addition, the length
and width of the
rake attachment (102) is not determinative. Generally any length and width of
the rake
attachment (102) that allows the attachment (102) to efficiently and
effectively rake an
asphalt repair area is contemplated. In one embodiment, it is contemplated
that the rake
attachment's (102) length will correspond to the length of the infrared
heating apparatus used
to heat the desired repair area often with a corresponding width to allow the
entire area to
essentially be raked in one pass. For example, in one embodiment, as depicted
in FIGS. 2-6,
the rake attachment will be approximately six (6) feet in length and around
four (4) feet in
width.
11
CA 02859339 2014-08-14
= = =
= -
Attorney Docket No. 29484-32
[050] Further, the length, width and shape of the tines or teeth (103) of
the rake
attachment (102) are not determinative. Generally any length, width or shape
teeth (103) that
are capable of effectively raking and scarifying the asphalt repair area are
contemplated. In
one embodiment, teeth (103) between about 4 inches and 7 inches are
contemplated. In one
embodiment, the teeth or tines (103) will be prescribed dimensions to maximize
the raking of
the repair area in order to rake the patch deeper and take out any cold spots
in the asphalt to
create a more uniform patch. For example, in one preferred embodiment, as
depicted in
FIGS. 2-6, the teeth will extend approximately 6 inches below the rake spine
(104) and are
designed to agitate between about 2" to about 4" of depth from the asphalt.
[051] In the depicted embodiment, the rake tines (103) are designed to be
removable and
replaceable from the rake spine (104). As can be best seen in FIG. 3, in an
embodiment, the
rake spine (104) comprises a hollow tube with a generally quadrilateral cross
section. The
tines (103) are inserted from above through holes in the spine (104) and are
then secured with
a clamping or screw mechanism from above. Thus, should a tine (103) become
damaged
(e.g., bent or broken) it can be removed from the spine (104) and replaced
with a new tine
(103). Further, in an alternative embodiment, this allows for the rake (102)
to utilize a
variety of tines (103) of different lengths for different jobs.
[052] The rake attachment (102) of the mechanized asphalt comb (101) is
attached to an
engineering vehicle (105). The term "engineering vehicle," as used herein,
shall include any
engineering vehicle or heavy equipment machine known to those of ordinary
skill in the art,
now or in the future, that is capable of moving or transporting materials.
Examples of
contemplated engineering vehicles (105) include, but are not limited to, skid
loaders or skid
steers, steamrollers, tractors, compact excavators, backhoe loaders,
bulldozers, excavators,
forklift trucks, loaders, and heavy-duty trucks. In a preferred embodiment,
the engineering
vehicle (105) will have one or more lift arms to which the rake attachment
will be attached,
12
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
although this is not determinative. For example, in the embodiment in which
the mechanized
asphalt comb (101) is attached to a steamroller, the rake attachment would be
attached in an
appropriate manner to the rolling apparatus.
[053] The form of attachment of the rake attachment (102) to the
engineering vehicle
(105) is not determinative. For example, the rake attachment (102) may be
bolted, screwed,
clipped, slotted or attached in another manner known to those of ordinary
skill in the art to
the engineering vehicle (105). Further, permanent, semi-permanent and
temporary forms of
attachment of the rake attachment (102) to the engineering vehicle (105) are
contemplated.
In the embodiments where the engineering vehicle (105) has one or more lift
arms, it is
contemplated that the rake attachment (102) will be attached to these
component parts of the
engineering vehicle (105).
[054] In certain embodiments, it is contemplated that the rake attachment
(102) of the
asphalt comb (101) will be attached directly to the engineering vehicle (105)
or a lift arm or
lift arms thereof. In other embodiments, as depicted in FIGS. 2-6, it is
contemplated that the
mechanized asphalt comb (101) will further comprise an arm (109). The function
of the arm
(109) of the mechanized asphalt comb (101) is to both connect and create a
certain distance
between the rake attachment (102) and the engineering vehicle (105) to allow
for
visualization of the raking activity by the vehicle operator and/or to limit
the need for the
vehicle (105) to enter the repair area or drive around the repair and rake
from both sides.
Thus, on one end, the arm (109) will be attached to an engineering vehicle
(105) and, on the
opposite terminating end, the arm (109) will be attached to the rake
attachment (102).
Another function of the arm (109) of the mechanized asphalt comb (101) is to
create a
loading support area for an individual to stand on while loading hot mix
asphalt from an
asphalt storage tank into the dumping container (106) of the mechanized
asphalt comb (101).
Similar to the rake attachment (102), it is contemplated that the arm (109)
may be comprised
13
CA 02859339 2014-08-14
õ .
. ,
Attorney Docket No. 29484-32
of steel or other heavy metal material known to those of ordinary skill in the
art. Further, the
dimensions of the arm (109) are not determinative. The arm (109) may be any
length, width
or shape to correspond with and link via attachment to the rake attachment
(102) and the
engineering vehicle (105), and in embodiments where the arm (109) has a
loading support
area, to provide a platform for a laborer to stand and work from. In the
embodiment of an
arm with a loading support area, it is also contemplated that the arm will
have side rail
supports, as shown in FIGS. 2-4, for added stability.
[055] In the embodiments of the mechanized asphalt comb (101) in which the
mechanized asphalt comb (101) is attached to a lift arm or lift arms of the
engineering vehicle
(105) (either directly or via an arm (109)), it is contemplated that the
mechanized asphalt
comb (101) will have a raised inactive (107) position (depicted in FIG. 6) and
lowered active
(108) position (depicted in FIGS 2 - 4). As demonstrated in FIG. 6, in the
raised inactive
position (107), the mechanized asphalt comb (101) is raised at a certain angle
above the
ground or asphalt pavement. This position allows the engineering vehicle (105)
to move
around freely without any risk of the mechanized asphalt comb (101) coming
into contact
with the ground and hampering the engineering vehicle's (105) mobility.
Further, as
demonstrated in FIGS. 2-4, in the lowered active position (108) the mechanized
asphalt comb
(101) is lowered to a position in which it can engage with, rake, and scarify
a given asphalt
repair area. It is contemplated that, in the embodiment of the mechanized
asphalt comb (101)
in which the comb (101) is attached to the lift arm(s) of an engineering
vehicle (105), the
operator of the engineering vehicle (105) will be able to position the
mechanized asphalt
comb (101) in the inactive raised position (107) and the active lowered
position (108), along
with a variety of positions in the range in between.
[056] Another contemplated component of the asphalt comb (101) is the
dumping
container (106). Embodiments of the asphalt comb (101) that contain a dumping
container
14
CA 02859339 2014-08-14
."
Attorney Docket No. 29484-32
(106) are depicted in FIGS. 2-6. As shown therein, the dumping container (106)
is a
receptacle for a certain volume of material. The dimensions and shape of the
dumping
container (106) of the asphalt comb (101) are not determinative; the dumping
container (106)
may take on any shape or dimensions that allow it to hold a given amount of
hot asphalt
therein when the asphalt comb (101) is in both its raised inactive (107) and
lowered active
(108) positions. In one embodiment, as depicted in FIGS. 2-4, it is
contemplated that the
dumping container 106) will have a slanted angle on the side of the dumping
container (106)
which faces the rake attachment (102), the angle facilitating both the loading
of a mixture
into and the dumping of a mixture from the dumping container (106). Further,
the material
that comprises the dumping container (106) is not determinative. Any material
known to
those of ordinary skill in the art that is capable of holding and retaining
hot asphalt is
contemplated. For example, in one embodiment, as depicted in FIGS. 2-6, the
dumping
container (106) will be comprised of steel or other heavy metal known to those
of ordinary
skill in the art.
[057] In one preferred embodiment, it is contemplated that the dumping
container (106)
will be mechanically moveable around a hinge point on the front of the dumping
container
(106). An embodiment of this hinge point is depicted in FIG. 5. In this
embodiment, an
operator of the engineering vehicle (105) will be able to automatically raise
and lower the
dumping container (106) around the hinge point in order to dump the material
contained
therein onto the ground at a position generally in front of the rake
attachment (102) of the
asphalt comb (101). Once the material contained in the dumping container is
distributed onto
the ground in front of the rake attachment (102) of the asphalt comb (101),
the dumping
container (106) can be lowered to increase visibility for the device operator.
[058] In one embodiment of the mechanized asphalt comb (101) in which the
asphalt
comb (101) is comprised of an arm (109), it is contemplated that the dumping
container (106)
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
will be located at a place generally close to the rake attachment (102) on the
arm (109). It
should be noted that the location of the dumping container (106) on the
mechanized asphalt
comb (101) is not determinative and any location on the rake attachment (102)
and/or the arm
(109) which allows for the dumping container (106) to freely move around its
hinge point and
distribute the material contained therein at a location generally in front of
or behind the rake
attachment (102) is contemplated. Similarly, in the embodiments of the
mechanized asphalt
comb (101) in which the mechanized asphalt comb (101) is directly attached to
the
engineering vehicle (105), it is contemplated that the dumping container (106)
will be
attached to either the rake attachment (102) or the engineering vehicle in
such a manner that
the asphalt or other material contained therein can be easily transported and,
if desired,
dumped into a position on the ground generally in front of the rake attachment
(102). This
allows for the material to be dumped in very close time proximity to the
initial agitation by
the rake, which eliminates the need for a worker to go and get the wheelbarrow
of material
and then dump it. Further, dumping of the material in proximity to the rake
attachment (102)
makes it easier for the rake attachment (102) to be used to agitate the new
material with the
old which can create a more dispersed and uniform blend of old and new
asphalt. Improved
distribution in the mix will often provide a patch with increased strength and
stability.
[059] In additional alternative embodiments, it is contemplated that the
asphalt comb
(101) will also comprise a cooling element known to those of ordinary skill in
the art.
Contemplated cooling elements include, but are not limited to, devices that
use air and or
water to lower the temperature of an exposed material. In these embodiments,
it is
contemplated that the cooling element will be located at a place on the
asphalt comb (101)
such that, when engaged, the cooling element can be applied to the recently
repaired asphalt
repair area. For example, in one embodiment, it is contemplated that the
cooling element will
16
CA 02859339 2016-10-18
Attorney Docket No. 29484-32
be located on the bottom of the arm (109) of the asphalt comb (101) behind the
rake
attachment (102) (i.e., closer to the engineering vehicle (105)).
[060] In yet another alternative embodiment, it is contemplated that the
mechanized
asphalt comb will also comprise a compression mechanism, such as a roller or
vibratory
compressor, known to those of ordinary skill in the art. In these embodiments,
the roller will
be utilized to compress the newly laid hot asphalt mix after it has been
deposited and leveled
onto the asphalt repair area.
[061] In still further alternative embodiments, it is contemplated that the
asphalt comb
(101) will further comprise a heating element known to those of ordinary skill
in the art.
Contemplated heating elements include, but are not limited to, infrared,
gaseous, and
electrical modalities. In these embodiments, it is contemplated that the
heating element,
when activated, will heat the rake attachment (102) such that the rake
attachment (102)
increases the overall temperature of the asphalt it comes into contact with
and rakes.
[062] In an embodiment, it is contemplated that the mechanized asphalt comb
will further
comprise an infrared heating pan (212). FIGS. 9 and 10 provide for two
different
embodiments of an integrated comb and heating panel (202). In the embodiment
of FIG. 9,
the heating panel (202) has been positioned to be placed on the lift arm of
the engineering
vehicle (105). The heating panel (202) to which the comb is integrated may
utilize standard
infrared or other heating elements and technologies as part of its heating
tray (212) as are
known in the art for the heating of asphalt. This can be, for example, a
heating chamber of
the type manufactured by Ray Tech Infrared Corp. as the "Tech 78" and
described at
www.raytechinfrared.com/sites/default/files/T78%20Brochure.pdf, or the
infrared pavement
restoration systems sold by Kasi Infrared at www.kasiinfrared.com/Infrared-
Asphalt-
Equipment.php#IR-120%2OWB.
17
CA 02859339 2014-08-14
.= =
i=
Attorney Docket No. 29484-32
[063] In the embodiment of FIG. 9, the integrated panel (202) includes
tines (103), as
discussed above, in the frame (222) of the heating tray (212). In this
embodiment, the tines
are moved by moving the engineering vehicle (105) and they will generally
cover all or
substantially all the side of the frame (222) opposing where the panel (202)
is connected to
the engineering vehicle (105).
[064] The arrangement of FIG. 9 allows for the engineering vehicle (105) to
arrive at the
location of asphalt to be repaired, to lower the panel (202) into position to
allow the tray
(212) to heat the asphalt, and then lower the panel (202) further so that the
tines (103) engage
the asphalt and it can be raked by simply driving the engineering vehicle
(105) in the
direction (301) to pull the tines through the heated section. As should be
apparent from the
above, the order of events is not strictly necessary and in alternative
embodiments the tines
can be lowered into contact with the asphalt (at any depth) before, during, or
after heating. In
a still further embodiment, the raking action can be performed with the
vehicle (105) while
the heating element is activated allowing for the device to first score and
then lift the asphalt.
[065] FIG. 10 provides an alternative embodiment of an integrated panel
(202). In this
panel (202), the frame includes at least one hydraulic cylinder (205) or other
linear movement
generating device such as, but not limited to, a pneumatic cylinder or a worm
drive, and the
tines (103) are not mounted in the frame (222) of the heating pan (212) but
are mounted on a
floating frame (215) which is connected thereto by the hydraulic cylinders
(205). The
cylinders (205) can be activated to cause the floating frame (215) and thus
the tines (103) to
traverse the area of the heating pan (212) in the direction (303). This
device, while more
complex, allows for the engineering vehicle (105) to be positioned at the
asphalt to be treated
and to heat and comb the asphalt without needing to move the engineering
vehicle (105).
[066] FIGS. 11-14 provide for a still further integrated device. The Tech
78, as discussed
above, while mounted on a skid steer or other tractor, does not provide that
the components
18
CA 02859339 2014-08-14
.='
..-
Attorney Docket No. 29484-32
are integrated to be used as a skid. That is, the components are not self-
contained and do not
provide a single integrated unit and instead require that components be spread
around the
engineering vehicle making the device complicated and costly to attach and
detach. Thus,
such a device essentially makes the underlying engineering vehicle a single-
purpose vehicle.
[067] FIGS. 11-14 provide for an integrated heating panel (244) that
provides all
elements of the heating and raking action as part of a single, connectable
skid or other
platform. This can be connected to the engineering vehicle (105) in a similar
manner to other
skids or attachments for the engineering vehicle (105). Thus, the engineering
vehicle (105)
can quickly attach and de-attach from the integrated heating panel and can be
used for a
variety of operations. In FIGS. 11-14, the various components of the
integrated heating panel
(422) are shown in blocks to show their relative positions as the specific
shape and style of
the components will depend on embodiment.
[068] As can be seen in the embodiment of FIGS. 11-13, the heating panel
(202) is as
shown in conjunction with FIG. 9. There are then attached two wing supports
(402) which
extend from the panel (202). These are used to support liquid propane tanks
(502) and
batteries (512) which serve to provide energy for heating of the elements in
the heating pan
(212). The wing supports (402) are preferably located behind the panel (202)
and on either
side of the engineering vehicle (105) around the position of its front axle as
shown in the
figures. This provides that the propane tanks (which are quite heavy) are
positioned beside
the vehicle (105), as opposed to in front of it, which can help keep the
vehicle (105) from
tipping forward. This can be particularly important where the vehicle (105) is
a skid steer or
other relatively small and lightweight vehicle.
[069] There is also provided an elevated rail (404). The rail (404)
generally connects
housings of the two wing supports (402) to each other, providing the device
with improved
stability and strength. There is also mounted on the rail (404) a control
panel (411) which
19
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
can provide a visual display on the action of the heating panel (202) as well
as providing for
an easy positioning of controls for controlling the heating panel (202).
[070] As would be apparent to one of ordinary skill in the art, the control
panel (411) can
be easily accessed by an individual in the engineering vehicle (105) by the
individual simply
reaching out to the control panel (411) from the cab of the engineering
vehicle (105). In a
still further embodiment, the panel (202) may be moveable and may be
positioned within the
cab of the vehicle (105) when the integrated panel (244) is positioned on a
lift arm of the
engineering vehicle (105) to provide for remote control.
[071] There is also shown mounted on the rail (404) a hydraulic motor
(413). This will
generally be a hydraulic motor of a type known to those of ordinary skill in
the art which is
capable of converting hydraulic force into rotary (or other) motion. The
hydraulic motor
(413) can attach to the auxiliary hydraulics of the engineering vehicle (105)
in a manner
understood by those of ordinary skill in the art to provide for further power
for the heating
pan (212) or for alternative power needs. The hydraulic motor (413) can be
attached to an
alternator (415) to provide this power depending on what form of power is
needed.
[072] As should be apparent from FIGS. 11-13, the integrated panel (244) is
attached
solely to the lift arm of the engineering vehicle (105) in a manner known to
those of ordinary
skill in the art. This allows for all elements of the panel (244) to be
quickly and easily
attached or detached from the vehicle (105) and does not require the vehicle
(105) to be
modified to carry the integrated panel (202).
[073] FIG. 14 shows an alternative embodiment of the integrated panel
(244). The
primary difference between this and the embodiment of FIGS. 11-13 is that the
panel (244) of
FIG. 14 utilizes the heating panel (202) of FIG. 10. In such an embodiment,
the hydraulic
cylinder(s) (205) may be powered by connection to main or auxiliary hydraulics
of the
engineering vehicle (105) in a manner known to those of ordinary skill.
Alternatively, the
CA 02859339 2014-08-14
,
_
Attorney Docket No. 29484-32
integrated panel (244) may include additional onboard hydraulic, pneumatic, or
other motive
systems to power them.
[074] Generally, an integrated panel (244) or heating panel (202) will not
include a
dumping container (106) as this adds increased complexity and weight to the
device. This
can be an issue where a skid steer or other relatively small engineering
vehicle (105) is
utilized as it can become front heavy. Further, as the auxiliary hydraulics of
the vehicle (105)
will generally be used as part of the energy supply for the heating pan (212),
there may not be
any auxiliary available to dump the dumping container (106). While such an
arrangement is
generally preferred, however, with a supply of asphalt being provided via
another engineering
vehicle (such as with a load bucket) or by hand, a dumping container (106) is
also integrated
into the integrated panel (244) or heating panel (202) in an alternative
embodiment.
[075] In use, the mechanized asphalt comb (101) provides a mechanized
method for
removing the top layer of an asphalt repair area, raking and scarifying an
asphalt repair area,
and/or applying new material to an asphalt repair area¨steps which, under the
traditional
infrared asphalt repair methodology, were performed manually. For example, in
one
embodiment, the asphalt comb (101) disclosed in FIGS. 2-6 is utilized as
follows. First, a
portion of asphalt repair material is loaded into the dumping container. In
the embodiment of
the mechanized asphalt comb (101) with an arm (109) with a loading support
area, this step
of loading can be taken by lowering the mechanized asphalt comb (101) into its
lowered
active position (108) and moving the mechanized asphalt comb (101) into a
position where
the edge of the dumping container (106) located closer to the rake attachment
(102) is at or
generally near the storage container for the hot asphalt. This orientation of
the mechanized
asphalt comb (101) and a storage container while hot asphalt mix is being
loaded into the
dumping container (106) is depicted in FIG. 7. Then a laborer steps up on the
loading
support area of the arm (109) and, from this position, is able to easily
shovel the hot mix
21
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
asphalt from the storage container into the dumping container (106). Once
loaded, the
laborer removes himself or herself from the arm (109) and the mechanized
asphalt comb
(101) is placed in the raised inactive position (107) so the engineering
vehicle (105) can
move freely.
[076] Second, while the mechanized asphalt comb (101) is in the raised
inactive position
(107), the engineering vehicle (105) is driven to an asphalt repair site
(i.e., an area of asphalt
that has been heated or will be heated by an infrared panel or other
methodology known to
those of ordinary skill in the art.).
[077] Then, in a third step, the mechanized asphalt comb (101) is lowered
into the active
lowered position (108) at the asphalt repair site and, while in the active
lowered position, the
engineering vehicle (105) is manipulated forwards and backwards in a manner to
rake and
scarify the asphalt located at the repair site with the rake attachment (102).
In this step, the
mechanized asphalt comb (101) will generally be maintained at the same angle
for each pass
on the repair area, however an operator may change the angle if a deeper or
shallower
scarifying depth is desired. Further, it is contemplated that, in certain
instances, only one
pass will be needed to sufficiently scarify and agitate the repair area. A
pass generally
includes lowering the asphalt comb (101) into an asphalt repair area and
either reversing the
engineering vehicle (105) or putting the engineering vehicle (105) in drive
such that the entire
asphalt repair area is agitated and raked by the rake attachment (102) in one
pass. In certain
embodiments, it is preferred that the scarification occur to a depth of about
two (2) to four (4)
inches to provide for a deep repair.
[078] If an embodiment of FIGS. 9-14 is used, the above steps may be
similarly
performed, but the devices for heating and raking are combined and no second
engineering
vehicle is needed. Thus, the steps may be integrated with each other in a
manner known to
22
CA 02859339 2014-08-14
= =
Attorney Docket No. 29484-32
one of ordinary skill. Similarly, the dumping steps may be eliminated, or
provided by
another vehicle or by hand, if a dumping container (106) is not included.
[079] This step of the mechanized asphalt comb (101) process has numerous
advantages
over the manual raking processes of the prior art. For example, a desired
depth and agitation
can be maintained throughout a given repair area and can be greater than can
be
accomplished manually. Further, since the agitation and scarification are
accomplished by
moving a mechanized asphalt comb (101) equipped engineering vehicle (105) back-
and-
forth, the time and laborer fatigue associated with the manual processes is
eliminated. In
addition, contrary to the manual method which inherently requires multiple
raking actions
and passes, the mechanized asphalt comb (101) is capable of sufficiently
agitating and
scarifying a repair area in one or two passes.
[080] Once the raking and scarification is completed, the mechanized
asphalt comb (101)
is raised into the raised inactive position (107). Then, in a fourth step, the
asphalt repair
material loaded into the dumping container (106) is dumped onto the repair
site in front of the
rake attachment (102) of the mechanized asphalt comb (101). In one embodiment,
this
dumping step will take place as follows. First, the mechanized asphalt comb
(101) will be
maneuvered into a position generally above the repair area and the mechanized
asphalt comb
(101) will be lowered to a position generally parallel to the repair area.
This orientation of
the mechanized asphalt comb in the dumping step is depicted in FIG. 8.
[081] Once in this position, the dumping container (106) will be raised via
its hinged
attachment to an angle at which the hot asphalt mix contained therein will
begin to be
deposited onto the repair area. Next, while the dumping container (106) is in
the raised
position, the engineering vehicle (105) will be manipulated forwards and
backwards in a
manner that will allow for generally all of the hot asphalt mixture contained
in the dumping
23
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
container (106) to be dumped onto the repair area. Alternatively, the mixture
may be dumped
in batches to provide extra mixture at particular points.
[082] After the dumping is complete, in a final step, the dumping container
(106) is
lowered from the raised position and the mechanized asphalt comb (101) is
lowered into the
lowered active position (109). Once lowered, the engineering vehicle is
manipulated
forwards and backwards in a manner to distribute the hot mix asphalt material
within in the
repair area. It is also contemplated that the mechanized asphalt comb (101)
will be used to
lute the repair area (i e., the hot asphalt mix in the repair area is leveled
with the surrounding
asphalt by having a luting attachment thereon which can swing below the tines
(103)). After
luting, the repair area will be compressed and allowed to cool. Alternatively,
the luting
process may still be performed by hand. In the embodiments in which the
mechanized
asphalt comb (101) comprises a cooling mechanism and a compressor, it is
contemplated that
these steps may be performed by the mechanized asphalt comb (101).
[083] In sum, the mechanized asphalt comb (101) described herein has
numerous
advantages over the manual raking process previously utilized in the art of
infrared asphalt
repairs. Utilizing this method, time is saved and the efficiency of the repair
process is
increased since an operator can rake a newly heated repair area in as little
as one pass.
Further, this method and device allows an operator to rake the patch deeper
and at a
consistent depth throughout the repair area compared to the known manual
methodologies.
This improvement is feasible because, among other things, the rake attachment
generally
corresponds in width to the repair area, is heavily constructed, and is
attached to a piece of
machinery that can provide a consistent downward pressure, i.e., it is not
subject to fatigue
like laborers in the manual raking process of the prior art.
[084] While the invention has been disclosed in conjunction with a
description of certain
embodiments, including those that are currently believed to be the preferred
embodiments,
24
CA 02859339 2014-08-14
Attorney Docket No. 29484-32
the detailed description is intended to be illustrative and should not be
understood to limit the
scope of the present disclosure. As would be understood by one of ordinary
skill in the art,
embodiments other than those described in detail herein are encompassed by the
present
invention. Modifications and variations of the described embodiments may be
made without
departing from the spirit and scope of the invention.
