Patent Application
20240083816
The present invention relates generally to roadway construction. More specifically, the present invention relates to ceramic sol-gel solutions that bind road materials.
Sol-gel is a process for producing solid materials. A liquid solution containing solid particles is transformed into a gel. Grout refers to a dense ceramic sol-gel solution that is used to fill gaps or reinforce existing structures. Grout generally consists of a mixture of water, cement, and sand. In road construction, grout is used to bind the road aggregate.
It is an objective of the present invention to provide a ceramic sol-gel grouting system that is applied to gravel roads, unimproved dirt roads, and sand roads. It is a further objective of the present invention to provide a ceramic sol-gel grouting system that will permanently grout and bind the road aggregate, dirt, dust, soil, crushed concrete, and recycled asphalt.
The present invention is a ceramic sol-gel grouting system. A dirt roadbed is tilled. A sol-gel coating is sprayed to the tilled roadbed. The crown of the roadbed is formed. A cross-linker is sprayed on the road. The roadbed is rolled. The sol-gel solution and cross-linker react to form a ceramic coating around the road aggregate. The ceramic coating forms a durable, permanent grout around the road aggregate. The ceramic coating reacts with carbon dioxide in the air to form calcium carbonate rock, capturing the carbon dioxide from the air.
All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
The present invention comprises a ceramic sol-gel (grouting) system. The ceramic sol-gel system is applied to gravel roads, unimproved dirt roads, or sand roads. The ceramic sol-gel system will permanently grout and bind the road aggregate, dirt, dust, crushed concrete, and recycled asphalt. The ceramic sol-gel system produces a nontoxic and non-polluting ceramic grouted road surface. The ceramic sol-gel system produces a hard, durable, permanent, non-slippery, and granular road surface. The ceramic-grouted road surface provides roadbed stability, surface durability, as well as water shedding. The grout shell surface (Sol-Gel) also provides direct air capture of carbon dioxide (CO2) and will convert the CO2 to calcium carbonate “rock.”
Referring to
Referring to
At step 201, a new or existing roadbed is prepared for sol-gel application. For example, an aggregate material may be laid in the intended location of the road.
At step 202, the top surface of the roadbed is tilled. For example, the top four inches of the roadbed is tilled to loosen the aggregate material. Tilling the roadbed allows Solution A 110 to fully drape, wrap, and envelope the roadbed aggregate and dust.
At step 203, a first solution, Solution A 110, is applied to the roadbed. Solution A 110 is sprayed onto the prepared roadbed. The Solution A 110 envelops the pieces of the aggregate material of the roadbed.
At step 204, the crown and shape of the road is formed. The crown of the road is a raised section, typically located at the center of the road.
At step 205, a second solution, Solution B 120, is applied. The Solution B 120 is sprayed onto the freshly formed road surface.
At step 206, the road is rolled. A road roller is used to compress the aggregate of the road.
At step 207, Solution B 120 cross links the coated aggregate. The Solution B 120 instantaneously cross links the Solution A 110 coating the road aggregate to form a hard, durable, permanent, and granular road surface.
At step 208, the road cures into a sol-gel coating. As Solution B 120 reacts with the Solution A 110, the mixture cures into a granular grouted road surface. The cured mixture forms a ceramic coating.
At step 209, the treaded road absorbs carbon dioxide (CO2) directly from the atmosphere. The CO2 is captured through direct air capture (DAC). As the sol-gel road surface cures, the ceramic grout forms and cures on the road. The cross-linked sol-gel is reactive with CO2 gas in the atmosphere. The surface of the grouted road will provide direct air capture and conversion of CO2, which hardens the treated road surface. The hardened road surface reacts with CO2 in the air and converts the CO2 to calcium carbonate rock. The reactant surface of the ceramic sol-gel coating will absorb and hold a portion of its weight in captured CO2. The coated road aggregate will absorb approximately 10 tons of CO2 per lane mile.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. It is to be understood that the steps in the present invention may be performed in any order, and the order of the steps may be modified without departing from the spirit and scope of the invention hereinafter claimed. It is to be understood that any steps in the present invention may be repeated without departing from the spirit and scope of the invention hereinafter claimed.
| Number | Date | Country | |
|---|---|---|---|
| 63375340 | Sep 2022 | US |
