Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02887171 2015-04-07
SYSTEM AND METHOD FOR ROADWAY PAVEMENT RESTORATION
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to and the benefit of U.S. Provisional Patent
Application No.
61/976,147 entitled "System and Method for Roadway Pavement Restoration" filed
on April 7,
2014, the entire disclosure of which is incorporated by reference herein.
This application cross-references U.S. Patent Appl. No. 13/167,888 entitled
"Asphalt Repair
System and Method" filed June 24, 2011 now issued as U.S. Pat. No. 8,556,536
on Oct. 15, 2013;
U.S. Patent Appl. No. 13/848,455 entitled "Asphalt Repair System and Method"
filed March 21,
2013 now issued as U.S. Pat. No. 8,562,247 on Oct. 22, 2013; U.S. Patent Appl.
No. 14/049,682
entitled "Asphalt Repair System and Method" filed October 9, 2013; U.S. Patent
Appl. No.
13/742,928 entitled "System and Method for Sensing and Managing Pothole
Location and Pothole
Characteristics" filed January 16, 2013; U.S. Patent Appl. No. 13/777,633
entitled "System and
Method for Controlling an Asphalt Repair Apparatus" filed February 26, 2013;
U.S. Patent Appl.
No. 13/931,076 entitled "Asphalt Brick Device and Method of Making Same" filed
June 28, 2013;
and U.S. Patent Appl. No. 29/461,750 entitled "Asphalt Repair Device" filed
July 26, 2013 now
issued as U.S. Design Pat. No. D700,633, each of the applications being
incorporated by reference
herein.
FIELD OF THE INVENTION
Embodiments of the present invention are generally related to roadway
maintenance and
repair, and, in particular, to a system and method for restoring asphalt
surfaces such as asphalt
roadways.
BACKGROUND OF THE INVENTION
Conventionally, repairing damaged roadways is done on an ad hoc basis
resulting in
inefficiencies and varying effectiveness. For example, repair of asphalt
surfaces is typically done by
removing a damaged section (e.g. a section surrounding a pothole) and re-
laying the section with
fresh asphalt or simply patching the area with an asphalt compound. Based on
the repair
capabilities and the experience of the repair crew, ambient grade temperature,
asphalt repair
material and the effectiveness of the repair equipment, the resulting roadway
repair will vary in
quality and effectiveness.
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Effective and efficient repair of asphalt roadway surfaces requires control of
several
variables based on the characteristics of the targeted repair site, ambient
conditions, capabilities of
the repair device and crew and operational requirements. Currently, asphalt
repair is performed
through application of heat to a targeted area of repair. The resulting
softened area (i.e. an area with
decreased hardness) is then better able to receive and adhere to replacement
or supplement asphalt
applied to the area. However, effective softening of the targeted area
requires applying heat in a
deliberate and controlled fashion adapted to the composition of the asphalt
involved, the outside
ambient temperature, the temperature of the targeted repair area, and the
degree of softening of the
targeted area achieved. If the targeted area is improperly heated or softened,
the replacement asphalt
will not adhere to the repair area and/or seam lines may result. Seam lines
are problematic because
they reflect a discontinuity between the repair and the asphalt roadway and
commonly result in
uneven pavement and pothole formation. In current practice, the heat required
to soften a targeted
asphalt area is a manual iterative process, in which a road crew member
measures softness by
driving a shovel into the asphalt to evaluate pliability. Such a process
widely varies in accuracy
based on, for example, the skills of the crew member and the location and
frequency of the shovel-
measurement.
Furthermore, the current asphalt repair process is energy and time
inefficient. The heat
source is manually positioned and oriented relative to the targeted repair
site, and heat applied to
bring the repair area to within a targeted temperature and softness range.
Typically, propane fueled
heaters are used to heat the repair area as part of a repair process requiring
a 4-5 man crew operating
over 3-4 hours using heavy equipment. The repaired area is left with a
perimeter seam and the
repair is guaranteed for 6-9 months.
In contrast, a more efficient asphalt repair process will minimize the time
required to bring
the material up to a required temperature and softness level while avoiding
overheating. If a
maximum temperature is exceeded (for example, approximately 375 deg. F),
volatile oils burn off
and the repair surface may be compromised. However, if the temperature is
increased too slowly,
more energy is consumed and crew on-site costs will increase.
One recently-developed approach to asphalt repair involves the use of electric-
powered
infrared heating of a distressed asphalt area followed by use of a
multipurpose asphalt processor
used to both till and screed the repaired asphalt surface. Such a system and
method is described in,
for example, U.S. Patent Nos. 8,556,533, 8,562,247 and D700,633, and U.S. Pat.
Appl. Nos.
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14/049,682 and 13/777,633, as cited above. This system and method requires a 2
man crew, takes
about 1 hour, requires less equipment and provides a seamless and permanent
repair that may be
guaranteed for 18 months. Furthermore, a greater volume of asphalt is recycled
than in conventional
techniques. Additionally, the use of electrically-powered infrared heating
yields a much reduced
environmental footprint relative to the use of propane. While effective, such
a system may be
enhanced to, for example, increase ease of use, reduce total time at a roadway
repair site, reduce
labor required and minimize roadway lane blockage while providing a seamless,
permanent asphalt
restoration far superior to conventional asphalt repair methods.
Thus, there is a long-felt need for a system and method that provides a system
and method
for preserving and/or restoring asphalt surfaces such as asphalt roadways that
is easy to use,
minimizes labor on site, reduces total time at a roadway repair site and
minimizes roadway lane
blockage. Further, there is a long-felt need for a system and method that
provides a more effective
and efficient rejuvenation and preservation of asphalt roadways thereby
yielding a more cost and
time effective utilization of material, labor, and equipment. Such rejuvenated
and preserved
roadways will be more robust and less prone to future damage.
SUMMARY OF THE INVENTION
In one embodiment of the invention, an asphalt restoration system and method
of asphalt
road restoration is disclosed. The method employs an infrared heating unit to
heat a repair area and
a processor that can both till and screed a repair area. After heating the
repair area, rejuvenation
materials are applied. The processor then tills the area and screeds it.
Lastly, a road roller is used to
pinch the joints of the repaired area. All required devices and materials
required for the method are
transportable by a single vehicle.
The phrases "at least one," "one or more," and "and/or" are open-ended
expressions that are
both conjunctive and disjunctive in operation. For example, each of the
expressions "at least one of
A, B and C," "at least one of A, B, or C," "one or more of A, B, and C," "one
or more of A, B, or
C" and "A, B, and/or C" means A alone, B alone, C alone, A and B together, A
and C together, B
and C together, or A, B and C together.
The term "a" or "an" entity refers to one or more of that entity. As such, the
terms "a" (or
"an"), "one or more," and "at least one" c,n be used interchangeably herein.
It is also to be noted
that the terms "comprising," "including," and "having" can be used
interchangeably.
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The term "asphalt", "asphalt mix" and "asphalt cement" and variations thereof,
as used
herein, refers to a composite material comprising aggregate and a binder used
in construction
projects to include road surfaces, parking lots and airports.
The term "aggregate" and variations thereof, as used herein, refers to coarse
particulate
material used in construction, to include crushed stone, gravel, sand, silt,
slag, recycled concrete,
geosynthetic aggregates and clay.
The term "binding agent" and variations thereof, as used herein, refers to any
material or
substance that holds or draws aggregate together to form a cohesive asphalt,
to include bitumen and
any "bituminous material."
The term "bulk asphalt" and variations thereof, as used herein, refers to
asphalt provided in
large quantities, typically by dump truck.
The term "automatic" and variations thereof, as used herein, refers to any
process or
operation done without material human input when the process or operation is
performed.
However, a process or operation can be automatic, even though performance of
the process or
operation uses material or immaterial human input, if the input is received
before performance of
the process or operation. Human input is deemed to be material if such input
influences how the
process or operation will be performed. Human input that consents to the
performance of the
process or operation is not deemed to be "material."
A "communication channel" refers to an analog and/or digital physical
transmission medium
such as cable (twisted-pair wire, cable, and fiber-optic cable) and/or other
wireline transmission
medium, and/or a logical and/or virtual connection over a multiplexed medium,
such microwave,
satellite, radio, infrared, or other wireless transmission medium. A
communication channel is used
to convey an information signal, for example a digital bit stream, from one or
several senders (or
transmitters) to one or several receivers. A communication channel has a
certain capacity for
transmitting information, often measured by its bandwidth in Hz or its data
rate in bits per second.
Communication channel performance measures that can be employed in determining
a quality or
grade of service of a selected channel include spectral bandwidth in Hertz,
symbol rate in baud,
pulses/s or symbols/s, digital bandwidth bit/s measures (e.g., gross bit rate
(signaling rate), net bit
rate (information rate), channel capacity, and maximum throughput), channel
utilization, link
spectral efficiency, signal-to-noise ratio rrwasures (e.g., signal-to-
interference ratio, Eb/No, and
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carrier-to-interference ratio in decibel), bit-error rate (BER), packet-error
rate (PER), latency in
seconds, propagation time, transmission time, and delay jitter.
The terms "communication device," "smartphone," and "mobile device," and
variations
thereof, as used herein, are used interchangeably and include any type of
device capable of
communicating with one or more of another device and/or across a
communications network, via a
communications protocol, and the like. Exemplary communication devices may
include but are not
limited to smartphones, handheld computers, laptops, netbooks, notebook
computers, subnotebooks,
tablet computers, scanners, portable gaming devices, phones, pagers, GPS
modules, portable music
players, and other Internet-enabled and/or network-connected devices.
The term "communication system" or "communication network" and variations
thereof, as
used herein, refers to a collection of communication components capable of one
or more of
transmission, relay, interconnect, control, or otherwise manipulate
information or data from at least
one transmitter to at least one receiver. As such, the communication may
include a range of
systems supporting point-to-point to broadcasting of the information or data.
A communication
system may refer to the collection individual communication hardware as well
as the interconnects
associated with and connecting the individual communication hardware.
Communication hardware
may refer to dedicated communication hardware or may refer a processor coupled
with a
communication means (i.e., an antenna) and running software capable of using
the communication
means to send a signal within the communication system. Interconnect refers
some type of wired or
wireless communication link that connects various components, such as
communication hardware,
within a communication system. A communication network may refer to a specific
setup of a
communication system with the collection of individual communication hardware
and interconnects
having some definable network topography. A communication network may include
wired and/or
wireless network having a pre-set to an ad hoc network structure.
The term "computer-readable medium" as used herein refers to any tangible
storage and/or
transmission medium that participate in providing instructions to a processor
for execution. Such a
medium may take many forms, including but not limited to, non-volatile media,
volatile media, and
transmission media. Non-volatile media includes, for example, NVRAM, or
magnetic or optical
disks. Volatile media includes dynamic memory, such as main memory. Common
forms of
computer-readable media include, for example, a floppy disk, a flexible disk,
hard disk, magnetic
tape, or any other magnetic medium, magfieto-optical medium, a CD-ROM, any
other optical
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medium, punch cards, paper tape, any other physical medium with patterns of
holes, a RAM, a
PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any
other
memory chip or cartridge, a carrier wave as described hereinafter, or any
other medium from which
a computer can read. A digital file attachment to e-mail or other self-
contained information archive
or set of archives is considered a distribution medium equivalent to a
tangible storage medium.
When the computer-readable media is configured as a database, it is to be
understood that the
database may be any type of database, such as relational, hierarchical, object-
oriented, and/or the
like. Accordingly, the disclosure is considered to include a tangible storage
medium or distribution
medium and prior art-recognized equivalents and successor media, in which the
software
implementations of the present disclosure are stored.
The term "display" refers to a portion of a screen used to display the output
of a computer to
a user.
The terms "determine", "calculate" and "compute," and variations thereof, as
used herein,
are used interchangeably and include any 'type of methodology, process,
mathematical operation or
technique.
The term "in communication with," as used herein, refers to any coupling,
connection, or
interaction using electrical signals to exchange information or data, using
any system, hardware,
software, protocol, or format, regardless of whether the exchange occurs
wirelessly or over a wired
connection.
The term "module" Its used herein refers to any known or later developed
hardware,
software, firmware, artificial intelligence, fuzzy logic, or combination of
hardware and software that
is capable of performing the functionality associated with that element.
The term "roadway" as used herein refers to roads of all capacity, whether
private or public,
of various pavement compositions to include concrete, asphalt, asphalt
concrete, and reclaimed
asphalt pavement.
The term "repair area" as used herein refers to any atypical or degraded
characteristic of a
prototypical roadway, to include potholes, ruts, crowns, upheaval, raveling,
shoving, stripping,
grade depressions, and cracking of various types to include line cracking and
alligator cracking.
The term "means" as used herein shall be given its broadest possible
interpretation in
accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim
incorporating the term
"means" shall cover all structures, materials, or acts set forth herein, and
all of the equivalents
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thereof. Further, the structures, materials or acts and the equivalents
thereof shall include all those
described in the summary of the invention, brief description of the drawings,
detailed description,
abstract, and claims themselves. Accordingly, a claim incorporating the
term "means" shall
cover all structures, materials, or acts set forth herein, and all of the
equivalents thereof. Further, the
structures, materials or acts and the equivalents thereof shall include all
those described in the
summary of the invention, brief description of the drawings, detailed
description, abstract, and
claims themselves.
The term "screen," "touch screen," or "touchscreen" refers to a physical
structure that
enables the user to interact with the computer by touching areas on the screen
and provides
information to a user through a display. The touch screen may sense user
contact in a number of
different ways, such as by a change in an electrical parameter (e.g.,
resistance or capacitance),
acoustic wave variations, infrared radiation proximity detection, light
variation detection, and the
like. In a resistive touch screen, for example, normally separated conductive
and resistive metallic
layers in the screen pass an electrical current. When a user touches the
screen, the two layers make
contact in the contacted location, whereby a change in electrical field is
noted and the coordinates of
the contacted location calculated. In a capacitive touch screen, a capacitive
layer stores electrical
charge, which is discharged to the user upon contact with the touch screen,
causing a decrease in the
charge of the capacitive layer. The decrease is measured, and the contacted
location coordinates
determined. In a surface acoustic wave touch screen, an acoustic wave is
transmitted through the
screen, and the acoustic wave is disturbed by user contact. A receiving
transducer detects the user
contact instance and determines the contacted location coordinates. The touch
screen may or may
not include a proximity sensor to sense a nearness of object, such as a user
digit, to the screen.
In one embodiment, a method of restoring asphalt in a road surface is
disclosed, the method
comprising: providing an asphalt restoration system comprising a vehicle with
a loading arm, a
heater, a heater power generator configured to communicate with the heater, a
road roller, and an
asphalt processor, wherein the vehicle is configured to simultaneously
transport the heater, heater
power generator, road roller, and asphalt processor; transporting the asphalt
restoration system to a
repair site comprising a repair area; offloading the heater from the vehicle
using the vehicle loading
arm; positioning the heater over the repair area; heating the repair area
using the heater to produce a
heated repair area; re-positioning the heater away from the heated repair
area; applying rejuvenation
material to the heated repair area; tilling the heated repair area with the
asphalt processor to break
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up the heated repair area and form a beveled edge on opposing sides of the
heated repair area;
leveling the heated repair area with a screed of the asphalt processor;
compacting the heated repair
area with the road roller; loading the heater onto the vehicle using the
vehicle loading arm; and
loading the road roller and asphalt processor onto the vehicle.
In another embodiment, a method of repairing a void in an asphalt road surface
is disclosed,
the method comprising: providing an asphalt restoration system comprising a
heater, a heater power
generator configured to communicate with the heater, and an asphalt processor;
transporting the
asphalt restoration system to a repair site comprising the void in an asphalt
road surface; positioning
the heater in proximity to the void; heating asphalt in proximity to the void
using the heater to
produce a heated repair area; re-positioning the heater away from the heated
repair area; tilling the
heated repair area with the asphalt processor to break up the heated repair
area; leveling the heated
repair area with a screed of the asphalt processor; and compacting the heated
repair area to create a
repaired asphalt road surface with a substantially uniform surface; wherein
the asphalt processor is
controlled remotely by a remote control device.
In another embodiment, an asphalt restoration system for repairing a void in
an asphalt road
surface is disclosed, comprising: a heater configured to heat asphalt in
proximity to the void to
produce a heated repair area; a generator configured to provide power to the
heater; an asphalt
processor configured to: i) till the heated repair area with a tiller to break
up the heated repair area,
and ii) level the heated repair area with a screed, the asphalt processor
configured to till with the
tiller in a first position of use and configured to level with a screed in a
second position of use; a
remote control device configured to remotely control the asphalt processor; a
road roller configured
to pinch the heated repair area; a vehicle with a loading arm, the vehicle
configured to
simultaneously transport the heater, the heater power generator, the asphalt
processor, and the road
roller; and wherein the loading arm is configured to offload the heater from
the vehicle.
This Summary of the Invention is neither intended nor should it be construed
as being
representative of the full extent and scope of the present disclosure. The
present disclosure is set
forth in various levels of detail in the Summary of the Invention as well as
in the attached drawings
and the Detailed Description of the Invention, and no limitation as to the
scope of the present
disclosure is intended by either the inclusion or non-inclusion of elements,
components, etc. in this
Summary of the Invention. Additional aspects of the present disclosure will
become more readily
apparent from the Detailed Description, particularly when taken together with
the drawings.
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The above-described benefits, embodiments, and/or characterizations are not
necessarily
complete or exhaustive, and in particular, as to the patentable subject matter
disclosed herein. Other
benefits, embodiments, and/or characterizations of the present disclosure are
possible utilizing,
alone or in combination, as set forth above and/or described in the
accompanying figures and/or in
the description herein below. However, the Detailed Description of the
Invention, the drawing
figures, and the exemplary claim set forth herein, taken in conjunction with
this Summary of the
Invention, define the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of
the
specification, illustrate embodiments of the invention and together with the
general description of
the invention given above, and the detailed description of the drawings given
below, serve to
explain the principals of this invention.
Figure 1 depicts the asphalt restoration system, according to one embodiment
of the
invention;
Figure 2 is a flow-chart of one method of use of the asphalt restoration
system, using the
embodiment of the asphalt restoration system of Figure 1;
Figure 3A depicts positioning the asphalt restoration system at a repair site,
a step of the
method of use of the asphalt restoration system of Figure 2;
Figure 3B depicts offloading a heating unit from a vehicle, a step of the
method of use of the
asphalt restoration system of Figure 2;
Figure 3C depicts positioning the heating unit over the repair area, a step of
the method of
use of the asphalt restoration system of Figure 2;
Figure 3D depicts heating the repair area, a step of the method of use of the
asphalt
restoration system of Figure 2;
Figure 3E depicts tilling the repair area by the asphalt processor, a step of
the method of use
of the asphalt restoration system of Figure 2;
Figure 3F depicts leveling the repair area by the asphalt processor, a step of
the method of
use of the asphalt restoration system of Figure 2;
Figure 3G depicts pinching the repair area by the road roller, a step of the
method of use of
the asphalt restoration system of Figure 2; and
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Figure 3H depicts loading the equipment onto the vehicle, a step of the method
of use of the
asphalt restoration system of Figure 2.
It should be understood that the drawings are not necessarily to scale. In
certain instances,
details that are not necessary for an understanding of the invention or that
render other details
difficult to perceive may have been omitted. It should be understood, of
course, that the invention
is not necessarily limited to the particular embodiments illustrated herein.
To assist in the understanding of the present invention the following list of
components and
associated numbering found in the drawings is provided herein:
Reference No. Component
2 Asphalt Restoration System
4 Vehicle
6 Vehicle Loading Arm
8 Heating Unit One
Heating Unit Two
12 Electrical Generator
14 Electrical Generator Fuel Container
16 Restoration (Asphalt) Processor
18 Road Roller
Asphalt Repair Material
22 Asphalt Repair Tools
24 Worker One
26 Worker Two
28 Power Connection One
Power Connection Two
32 Repair Site
34 Repair Area One
36 Repair Area Two
10 DETAILED DESCRIPTION
Figure 1 depicts the Asphalt Restoration System 2 at Repair Site 32 comprising
Repair Area
One 34. Asphalt Restoration System 2 comprises Vehicle 4 with Vehicle Loading
Arm 6. Vehicle 4
is configured to transport Heating Unit One 8, Heating Unit Two 10, Electrical
Generator 12,
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Electrical Generator Fuel Container 14, Restoration (Asphalt) Processor 16,
Road Roller 18,
Asphalt Repair Material 20, Asphalt Repair Tools 22, Worker One 24 and Worker
Two 26.
Vehicle 4 may be any commercially-available vehicle capable of transporting
the devices
and materials described, such as a commercial-grade truck. Vehicle 4 is
equipped with a Vehicle
Loading Arm 6 that is configured to off-load and on-load one or more heating
units, such as
Heating Unit One 8 and Heating Unit Two 10, or other components. In one
embodiment, the
Vehicle 4 includes outriggers to increase stability of the Vehicle 4 during
loading operations. In one
embodiment, the Vehicle 4 may include towed vehicles, e.g. a flatbed trailer,
to transport one or
more components, e.g. the Restoration Processor 16. The Vehicle Loading Arm 6
and associated
controls (such as hydraulic, electrical) are any of those known to one skilled
in the art. In one
embodiment, the Vehicle Loading Arm 6 is a lift or a ramp, e.g. a hydraulic
lift or a hydraulic ramp.
Each of Heating Unit One 8 and Heating Unit Two 10 comprise heating elements
configured
to heat asphalt pavement. Each of Heating Unit One 8 and Heating Unit Two 10
are electrically
powered infrared heating units, powered by Electrical Generator 12, and are
mounted on wheels so
as to be readily positioned by a single worker. Such wheels may have wheel-
locks to fix the
position of the Heating Unit One 8 and Heating Unit Two 10 at a user-selected
location, e.g. above
Repair Area One 34 and Repair Area Two 36, respectively. In one embodiment,
one or both of
Heating Unit One 8 and Heating Unit Two 10 are motorized or otherwise
configured to move
completely or partially without force by a user or worker. A more detailed
description of the
Heating Unit One 8 and Heating Unit Two 10 is found in the afore-mentioned
U.S. Pat. Nos. U.S.
Pat. No. 8,556,536 and U.S. Pat. Appl. No. 13/777,633.
The Electrical Generator 12 is mounted on Vehicle 4 and is powered by fuel,
such as diesel,
as stored in Electrical Generator Fuel Container 14. The Electrical Generator
12 is engaged with
Heating Unit One 8 and/or Heating Unit Two 10 via Power Connection One 28 and
Power
Connection Two 30, respectively. Power Connection One 28 and Power Connection
Two 30 are
any commercially-available electrical connections, to include quick-connect
power connectors and a
connection which pivots with the direction of the heating units. In one
embodiment, the Electrical
Generator 12 is a 36 kW generator. In one embodiment, one or both of the Power
Connection One
28 and Power Connection Two 30 are engaged with a drum or roller to facilitate
the unwinding
and/or winding-up of the Power Connection One 28 and/or Power Connection Two
30.
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In an alternate embodiment, the Elrxtrical Generator 12 is not mounted on
Vehicle 4, e.g. it
may be provided as a stand-alone power unit or mounted with the heating unit.
In one embodiment,
one or more of the Heating Unit One 8 and Heating Unit Two 10 heat asphalt by
other than infrared
means, e.g. by propane via propane heaters or by convection heating. In one
embodiment, one or
more of the Heating Unit One 8 and Heating Unit Two 10 heat asphalt by other
than propane
means, e.g. by infrared heating.
Restoration Processor 16 is a device which functions to both till and screed a
repair area,
such as Repair Area One 34. More specifically, the Restoration Processor 16
tills a repair area so as
to produce a beveled edge at the perimeter of the repair area. Such a beveled
edge results in a
seamless surface interface between the worked repair area and the unworked
repair area. A more
detailed description of the Restoration Processor 16 is found in the afore-
mentioned U.S. Pat. Nos.
8,556,536; 8,562,247; 8,714871 and D700,633.
Asphalt Repair Material 20 comprises asphalt, aggregate and binding agent in
any form, to
include as pellets and strips. In one embodiment, the method of the disclosure
and/or the device of
the disclosure uses an asphalt brick device and method of manufacture as
described in the afore-
mentioned U.S. Pat. Appl. No. 13/931,076.
Asphalt Repair Tools 22 are tools typically used in asphalt repair jobs,
comprising rakes and
shovels.
In one embodiment, one or more components are automated and/or remotely-
operated. For
example, Heating Unit One 8 and/or Heating Unit Two 10 may be operated through
automatic
controls with assistance of a user such as Worker One 24. In one embodiment,
the automatic and/or
semi-automatic operation of the Heating Unit One 8 and/or Heating Unit Two 10
is that as
described in the afore-mentioned U.S. Pat. Appl. No. 13/777,633. In one
embodiment, one or both
of the Road Roller 18 and Restoration Processor 16 are automated and/or
remotely-operated, such
as by the devices and methods of operation thereof as described in U.S. Pat.
Nos. 8,403,594 to
Neumann, 5,921,708 to Grundl, 8,267,619 to Munz and U.S. 7,549,821 to Hall,
the entire
disclosures of each of which are incorporated by reference herein. The control
of the remotely-
operated afore-mentioned U.S. Pat. Appl. No. 13/777,633. In one embodiment,
one or both of the
Road Roller 18 and/or Restoration Processor 16 are controlled by a
communication device and/or a
communication system by way of a user display or a user screen. For example, a
user may carry or
hold a display which presents positional data regarding the Restoration
Processor 16 and allows the
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user, e.g. by way of a joystick, to manipulate the operation of the
Restoration Processor 16 (such as
moving between a tilling state and a screed state.) In one embodiment, the
user controls the Road
Roller 18 and/or Restoration Processor 16 through wireless communication
means. In one
embodiment, the system 2 and/or one or more components e.g. processor 16,
comprise a computer-
readable medium.
In one embodiment, one or more remote control devices to control one or more
of the
elements/components of the system 2 may comprise any known means or devices
for automatic or
semi-automatic control, such as joysticks, buttons, switches and knobs, and
any known means or
devices to monitor or control status thereof, e.g. displays, gauges, lights
and sounds.
In one embodiment, the system and/or components thereof may communicate with a
control
base station that may be located on-site (e.g. on the vehicle 4) or remotely
(e.g. at the dispatch site
of vehicle 4, or at the company fleet headquarters.) The control base station
may comprise the
above monitoring and/or control components. In some embodiments, the control
base station may
be used to control and monitor multiple asphalt restoration systems 2
operating at different repair
sites, reducing the need for personnel at a given site.
Figure 2 is a flowchart of a general order of one method 100 of use of the
asphalt restoration
system, using the embodiment of the asphalt restoration system of Figure 1.
The method will be
described with reference to Figs. 1-3. The method starts with Step 102 and
ends with Step 124.
Figures 3A-G provide additional detail regarding most steps of the method 100.
The method 100
can include more or fewer steps or can arrange the order of the steps
differently than those shown in
Fig. 1.
At step 104, an Asphalt Restoration System 2 is provided, as described above.
The Asphalt
Restoration System 2 is self-contained in a single Vehicle 4, which, among
other things, minimizes
cost, reduces the footprint of the equipment to include reducing roadway lane
blockage, and
minimizes the logistical support required as compared with conventional
techniques which require
multiple vehicles.
At step 106 as depicted in Fig. 3A, the Asphalt Restoration System 2, as
transported by
Vehicle 4, is positioned at Repair Site 32 comprising Repair Area One 34 and
Repair Area Two 36.
In one embodiment, the selection and/or identification of a repair site may be
in the manner
described in the afore-mentioned U.S. Pat. Appl. No. 13/742,928. In one
embodiment, the repair
13
CA 02887171 2015-04-07
area, i.e. the distressed area, comprises an asphalt void of no more than
three (3) inches in depth. In
another embodiment, the distressed area comprises a void of no more than six
(6) inches in depth.
At step 108 as depicted in Fig. 31'3, the Vehicle Loading Arm 6 is used to off-
load one or
more heating units at Repair Site 32. In Fig. 3C, Heating Unit One 8 is
depicted as engaged with
Vehicle Loading Arm 6 as it is off-loaded from Vehicle 4. Heating Unit Two 10
is shown still
mounted on Vehicle 4. Repair Site 32 is shown comprising Repair Area One 34
and Repair Area
Two 36. In one embodiment, Worker One 24 may manage traffic flow while Worker
Two 26 off-
loads one or both of heating units. Note that the far right lane of Repair
Site 32 remains open to
traffic while the two left lanes are closed to effect the repair of repair
Site 32.
At step 110 as depicted in Fig. 3C, each of the Heating Unit One 8 and Heating
Unit Two 10
are positioned over Repair Area One 34 and Repair Area Two 36, respectively.
Further, each of the
Heating Unit One 8 and Heating Unit Two 10 are in communication with
Electrical Generator 12,
as mounted on Vehicle 4, via Power Connection 28 and Power Connection Two 30,
respectively.
One or both of Power Connection 28 and Power Connection Two 30 may be quick-
connect type
connectors. Throughout the method 100, two workers are required, that is
Worker One 24 and
Worker Two 26. In an alternate embodiment, one worker is required. In one
embodiment, the Power
Connection 28 and/or Power Connection Two 30 additionally or alternately
provide other-than-
electrical connections, e.g. a hydraulic connection to enable hydraulically-
assisted movement and/or
positioning of the Heating Unit One 8 and/or Heating Unit Two 10. In one
embodiment, the Heating
Unit One 8 and/or Heating Unit Two 10 are fitted with sensors, actuators
and/or displays to control
and/or monitor the heating unit. For example, such sensors may monitor/control
the temperature or
energy output of a heating unit and may re-position the height of a heating
unit above a repair area.
In one embodiment, the control and/or monitoring of one or both Heating Unit
One 8 and Heating
Unit Two 10 is as described in the afore-mentioned U.S. Pat. No. 8,801,325 and
U.S. Pat. Appl. No.
13/777,633. For example, an automatic controller is used to monitor and manage
the heating time,
heater orientation, heater temperature, repair area temperature, and/or repair
area softness/hardness.
At step 112 as depicted in Fig. 3D, each of the Repair Area One 34 and Repair
Area Two 36
are heated by Heating Unit One 8 and Heating Unit Two 10, respectively. In one
preferred
embodiment, the heating time is between 10 and 30 minutes. In a more preferred
embodiment, the
heating time is between 10 and 25 minutes. In a most preferred embodiment, the
heating time is
between 15 and 25 minutes. In one preferred embodiment, the repair area is
heated to a temperature
14
CA 02887171 2015-04-07
between 275 and 425 degrees Fahrenheit. In a more preferred embodiment, the
repair area is heated
to a temperature between 300 and 400 degrees Fahrenheit. In a most preferred
embodiment, the
repair area is heated to a temperature between 325 and 375 degrees Fahrenheit.
In another preferred
embodiment, the repair area is heated to a temperature of at least 325 degrees
Fahrenheit. Each of
the Heating Unit One 8 and Heating Unit Two 10 are in communication with
Electrical Generator
12, as mounted on Vehicle 4, via Power Connection 28 and Power Connection Two
30,
respectively. Note that each of Restoration Processor 16, Road Roller 18,
Asphalt Repair Material
20 and Asphalt Repair Tools 22 have been offloaded from Vehicle 4 for use at
Repair Site 32. At
the conclusion of step 112, the repair area is pliable.
At step 114, after removing the Heating Unit One 8 and Heating Unit Two 10
from
respective Repair Area One 34 and Repair Area Two 36, these repair areas may
be raked (e.g. to
remove any asphalt crust) and/or rejuvenation materials applied. During this
step, the repair area is
rejuvenated. Rejuvenation materials may comprise materials that provide
additives and/or
rejuvenators that strengthen bonding between the worked (healed) asphalt and
the un-worked
(surrounding) asphalt, such as rejuvenation strips, and/or polymer bonding
pellets. The polymer
bonding pellets are sprinkled on the worked area before application of the
rejuvenation strips, and
function to supplement the strips to further reinforce the seamless fusion
between the healed area
and the existing asphalt and provide added rigidity to prevent, e.g., rutting.
In one embodiment,
rejuvenation materials comprise RxEHAB oil strips, polymer bonding pellets and
recycled asphalt
pavement (RAP). In another embodiment, the devices and methods of the afore-
mentioned U.S. Pat.
Appl. No. 13/931,076 are used at step 114. For example, modular asphalt bricks
are applied to the
repair area. In one embodiment, the rejuveaation materials are pre-packaged.
At step 116 as depicted in Fig. 3E, the Repair Area One 34 and Repair Area Two
36 are
tilled using the Restoration Processor 16, as described in the afore-mentioned
U.S. Pat. Nos.
8,556,536; 8,562,247; D700,633 and U.S. Pat. Appl. No. 14/049,682. In this
step, the rejuvenated
repair area is processed in-place wherein a homogenous mix of processed
asphalt is created (much
like that produced by a batch plant.) Among other things, the Restoration
Processor 16 produces a
beveled edge at the perimeter of the repaired area, which enables a seamless
edge between the
worked (healed) and un-worked (surrounding) asphalt. As discussed above, in
one embodiment, the
tilling operation of the Restoration Processor 16 is automated and/or remotely-
operated. In one
embodiment, rejuvenation materials are alternatively or additionally applied
during and/or after step
CA 02887171 2015-04-07
116. In one embodiment, at the completion of step 116 the repair area presents
an area with a
homogenous mix with a consistency similar to new asphalt.
At step 118 as depicted in Fig. 3F, the Restoration Processor 16 is used to
screed and level
each of Repair Area One 34 and Repair Area Two 36, as described in the afore-
mentioned U.S. Pat.
Nos. 8,556,536; 8,562,247; D700,633 and U.S. Pat. Appl. No. 14/049,682. The
existing (unworked)
asphalt is used by the Restoration Processor 16 as a grade reference. As
discussed above, in one
embodiment, the screed and level operation of the Restoration Processor 16 is
automated and/or
remotely-operated. In one embodiment, rejuvenation materials are alternatively
or additionally
applied during and/or after step 118.
At step 120 as depicted in Fig. 3G, one or both of Repair Area One 34 and
Repair Area Two
36 are compacted (aka pinched) by Worker One 24 using Road Roller 18. That is,
the beveled edge
between the worked and un-worked asphalt is compressed from the surface
downwards, therein
"pinching" the beveled edge joint and further realizing a seamless asphalt
repair. As discussed
above, in one embodiment, the pinch/rolling operation of the Road Roller 18 is
automated and/or
remotely-operated.
At step 122 as depicted in Fig. 3H, all equipment and personnel that comprise
the Asphalt
Restoration System 2 are loaded onto Vehicle 4. Such loading includes loading
of each of Heating
Unit One 8 and Heating Unit Two 10 via Vehicle Loading Arm 6. The method 100
ends at step 124.
In one embodiment, one or more of the components are not carried by a single
vehicle 4, e.g.
the road roller 18 may be transported separately. In one embodiment, the
asphalt repair process does
not require the exporting (e.g. hauling away) of excavated asphalt. In one
embodiment, the asphalt
repair process is non-volatile. In one embodiment, the asphalt repair process
is compliant with one
or more green industry standards and/or one or more OSHA standards.
In some embodiments, the automatic or semi-automatic control of systems or
components,
as described above, is implemented by computer hardware, software, or a
combination thereof.
16
