FORMING A PAVED SURFACE WITH AN EMBEDDED TUBULAR BODY

Abstract

A method for building a surface with an embedded tubular body includes applying a first layer of a first material to a first surface and applying a tubular body. The tubular body can be applied at a top surface of the first layer or the tubular body can be applied at a top surface or within the first surface.

Description

TECHNICAL FIELD

The present disclosure relates generally to systems, methods, and apparatuses for forming a paved surface with an embedded tubular body. The tubular body can be a communication line, such as a fiber optic cable. The paved surface can be a road, parking garage, walking pathway, or any other man-made surface. The present disclosure generally relates to deploying the tubular body as part of the process to form the paved surface.

BACKGROUND

Communication lines or communication cables (i.e., examples of tubular bodies) provide useful conduits to transfer information (e.g., audio, visual, etc.) using modern technology. An example of a communication line is a fiber optic cable. The deployment and installation of communication lines, however, can be challenging for several reasons. For example, communication lines may need to extend over relatively long distances to, e.g., provide telecommunications to a commercial or residential building. Additionally, the communication lines may need to be accessible (e.g., for maintenance or repairs). At the same time, however, the communication lines may need to be protected from the environment and are often preferred to be hidden from view.

The usual process for installing a communication cable over a relatively long distance may include extruding plastic core tubes around, e.g., fibers, helically wrapping the tubes around a central strength member, building up several layers of protective sheathing, surrounding the sheathing with a protective material (armor) such as steel, and surrounding the armor with a heavy polymer jacket. Once a cable is manufactured, it can be pulled through conduits, hung along telephone poles, and/or buried inside trenches. Additional possibilities include what is known as “microtrenching” (see e.g., International Patent Application Publication No. 09/935,346), where an small trench is cut into the road surface or the ground. The cable is then installed within the micro-trench or installed on a roadway in the layers of protective sheathing as described above. Another example is described in U.S. Patent Application Publication No. 2002/0038716 where a flat fiber conduit is used for further protection.

The use of armor and other materials can increase the weight, fabrication cost, and installation foot-print of the communication cable. The larger installation footprint often requires significant disruption and repair of the installed route, each of which can contribute to higher installation cost.

When installing below the surface, communication cables can either be directly buried or installed into a conduit to further protect the cable. As noted above, the cable and conduit are often installed by trenching into the ground. The use of the conduit requires the added cost and overhead of conduit installation along with the fiber cable manufacturing and installation. Additionally, cutting the micro-trench adds expense and time to the installation process.

Plowing, direct burial, or other similar cable installation methods often require an array of machines. For example, a machine that utilizes a cutting blade to trench through soil or other natural ground substances may be needed. The communication cable may be installed in a process described in French Patent No. 2,762,155, which involves: (i) cutting a trench, (ii) burying a cable in the trench; and then (iii) backfilling the trench with a filler material suitable for the ground surface. This installation technique may cause significant disruption to local roadway infrastructure with attendant business impacts and transportation delays.

Installing a communication cable by micro-trenching is similar to a trenching or plowing install, but the cutting tool and ground opening are smaller. Less filler material may also be required. The micro-trenching installation technique is mainly used on roadways and often utilizes a heavy duty diamond saw blade that cuts a narrow (e.g., only a few inches wide) section of a roadway or similar surface to a predetermined depth depending on the location. A communication cable is installed or microduct is inserted for later filling with a communication cable. After that, the micro-trench is backfilled with an aggregate and another acceptable material. The risks of this technique (e.g., as described in International Patent Application Publication No. 09/935,346) include accidentally severing an existing utility line, damaging the integrity of the road surface, and risks to installers due to traffic and other safety concerns. Micro-trenching is not preferred in surfaces such as in private roads, shallow road surfaces, bridges, and tunnels, to name a few.

The present disclosure is directed to overcoming these and other problems of the prior art and may provide a more efficient and/or more robust technique to deploy a tubular body, such as a communication line, in or on a paved surface.

SUMMARY

Embodiments of the present disclosure may address and overcome one or more of the above shortcomings and drawbacks by providing methods, systems, and apparatuses related to forming a paved surface with an embedded tubular body.

In an exemplary embodiment, a method for building a surface comprising an embedded tubular body includes applying a first layer of a first material to a first surface and applying a tubular body at one of: a top surface of one of the first layer, within the first layer, and a top surface of the first surface. In some embodiments, the first material includes gravel and the first surface includes earth. In some embodiments, the first material includes asphalt and the first surface includes a gravel layer. In some embodiments, the first material includes asphalt and the first surface includes an asphalt layer. In some embodiments, the first material includes concrete and the first surface includes a gravel layer.

In some embodiments, applying a tubular body at a top surface of one of the first layer and the first surface includes applying the tubular body onto the top surface of the first surface using an apparatus that moves along the top surface of the first surface while the tubular body is being applied along the top surface of the first surface, the tubular body possessing a bottom face and a top face, the bottom face contacting the top surface of the first surface and the top face being above the top surface of the first surface. In some embodiments, applying a tubular body at a top surface of one of the first layer and the first surface includes applying the tubular body onto the top surface of the first layer using an apparatus that moves along the top surface of the first layer while the tubular body is being applied along the top surface of the first layer, the tubular body possessing a bottom face and a top face, the bottom face contacting the top surface of the first layer and the top face being above the top surface of the first layer. In some embodiments, the method can further include compacting the first layer in response applying the tubular body onto the top surface of the first layer. In some embodiments, the method can further include using the apparatus to compact the first layer.

In some embodiments, applying a tubular body at a top surface of one of the first layer and the first surface includes unspooling a tubular body spool. In some embodiments, the method further includes removing a second surface to reveal the first surface underneath.

In another exemplary embodiment, an apparatus for building a surface comprising an embedded tubular body includes a main body moveable in an advancing direction, the main body possessing a forward end and a read end, a plurality of rotatable bodies that contact the surface when the main body moves in the advancing direction, the plurality of rotatable bodies supporting the main body, the plurality of rotatable bodies all contacting the surface at a plurality of respective contact points on the surface, a tubular body holder configured to deploy a tubular body onto the surface, the tubular body holder being mounted on the main body, the tubular body configured to be deployed by the tubular body holder to contact the surface at a line contact point, and a road building element configured to perform a step to build the surface. In some embodiments, the tubular body holder and the rotatable bodies are configured such that the line contact point is coplanar with the plurality of respective contact points on the rotatable bodies. In some embodiments, the rotatable bodies comprise a plurality of wheels, the plurality of wheels rotating when the main body moves in the advancing direction.

In some embodiments, the tubular body holder comprises a rotatable spool that rotates to deploy the tubular body onto the surface. In some embodiments, the apparatus further includes a line guide connected to the forward end of the main body, the line guide comprising a hole, wherein the tubular body passes through the hole of the line guide before the tubular body contacts the surface.

In some embodiments, the road building element is a roller configured to compact a first layer to a first surface, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface ahead of the road building element as the main body advances. In some embodiments, the apparatus of claim 12, wherein the road building element is a dump truck configured to store and dump one of asphalt and concrete. In some embodiments, the road building element comprises a nozzle configured to distribute tack coat onto a first surface. In some embodiments, the road building element is a miller configured to destroy a layer of an existing road, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface behind the road building element as the main body advances. In some embodiments, the road building element is a sweeper configured to remove debris from a first surface, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface behind the road building element as the main body advances.

In yet another exemplary embodiment, a system for embedding a tubular body during a method of building a man-made surface includes a tubular body holder configured to deploy the tubular body onto a layer of the surface, the tubular body holder being configured to be mounted onto a vehicle configured to perform a step to build a man-made surface, the tubular body configured to be deployed by the tubular body holder to contact the surface at a line contact point, the tubular body holder comprising a rotatable spool that rotates to deploy the tubular body onto the surface as the vehicle advances.

Additional features and advantages of the disclosed technology will be made apparent from the following detailed description of illustrative embodiments that proceeds with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing and other aspects of the present disclosure are best understood from the following detailed description when read in connection with the accompanying drawings. For the purpose of illustrating the disclosed technology, the drawings shows some example embodiments, it being understood, however, that the disclosed technology is not limited to the specific instrumentalities disclosed. Included in the drawings are the following Figures:

FIG. 1 illustrates a tubular body embedded in a road;

FIG. 2 illustrates a cross-section of a road according to an embodiment of the disclosure.

FIG. 3 is a flow chart illustrating a method of building a surface according to an embodiment of this disclosure;

FIGS. 4A-4G illustrate locations where the tubular body can be located within a cross-section of a road according to embodiments of the disclosure;

FIG. 5 illustrates a perspective view of a tubular body deployment apparatus according to embodiments of the disclosure;

FIG. 6 illustrates a roller machine equipped with a tubular deployment apparatus according to embodiments of the disclosure; and

FIG. 7 illustrates an asphalt paver machine equipped with a tubular deployment apparatus according to embodiments of the disclosure.

DETAILED DESCRIPTION

The present disclosure describes systems, methods, and apparatuses for forming a paved surface with an embedded tubular body. In disclosed embodiments, a tubular body is embedded in a road, which is an example of a paved surface. The paved surface also could be, e.g., a parking lot, a pathway, an airport runway, or any other man-made surface. The tubular body can be embedded at any stage of the roadbuilding (or other paved surface-building) process, whether the road-building process is used to build a new road, repave an existing road, or to add another layer to an existing road. Further, in disclosed embodiments, equipment used during the road-building process can be modified to include an apparatus for deployment of a tubular body.

Although certain examples of the disclosed technology are explained in detail, it is to be understood that other examples, embodiments, and implementations of the disclosed technology are contemplated. Accordingly, it is not intended that the disclosed technology is limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The disclosed technology can be implemented in a variety of examples and can be practiced or carried out in various ways. In particular, the presently disclosed subject matter is described in the context of forming a road with an embedded tubular body. The present disclosure, however, is not so limited, and can be applicable to other applications. The present disclosure, for example and not limitation, can include forming any paved surface with an embedded tubular body, including a parking lot, a pathway, an airport runway, or any other man-made surface. Such implementations and applications are contemplated within the scope of the present disclosure. Accordingly, when the present disclosure is described in the context of forming a road with an embedded tubular body, it will be understood that other implementations can take the place of those referred to.

FIG. 1 illustrates a tubular body embedded in a road. As indicated by the dotted lines in FIG. 1, the tubular body 150 is underneath the base layer 101 of the road. The tubular body 150 can be deployed towards the edge of the road. For example, the tubular body 150 can be embedded near the shoulder of the road. This can beneficially decrease forces exerted on the tubular body 150 by vehicles traveling on the road. In other embodiments, the tubular body 150 can be deployed in the center of the road (e.g., beneath the painted road markings) or in any other location of the road. The tubular body 150 can extend generally longitudinally in parallel to the direction of traffic, as shown in FIG. 1.

FIG. 2 illustrates a cross-section of a road according to an embodiment of this disclosure. Paved surfaces can include many layers. In the embodiment illustrated in FIG. 2, the paved surface is a road that includes a base layer 101, a sub-base layer 102, a sub-grade layer 103, and an earth layer 104. The base layer 101 can include one or more layers of an asphalt layer and/or a concrete layer. The sub-base layer 102 can include one or more layers of a gravel layer. For example, in some embodiments, the sub-base layer 102 can include a layer of course gravel and a layer of finer gravel. The sub-grade layer 103 can include one or more layers of compacted soil. The earth layer 104 can be the earth beneath the road.

FIG. 3 is a flow chart illustrating a method 300 of building a surface, such as a road, comprising an embedded tubular body according to an embodiment of this disclosure. As described in further detail with respect to FIGS. 4A-4G, a tubular body 150 can be embedded within any layer of the road and/or in-between any layers of the road during the road building process. As shown in FIG. 3, at step 301, the method 300 of building a road can include applying a first layer of a first material to a first surface. At step 302, the method 300 can include applying a tubular body at one of: a top surface of the first layer, within the first layer, and a top surface of the first surface. In some embodiments, the first material can include gravel and the first surface can include earth. In some embodiments, the first material can include asphalt and the first surface can include a gravel layer. In some embodiments, the first material can include asphalt and the first surface can include an asphalt layer. In some embodiments, the first material can include concrete and the first surface can include a gravel layer.

As illustrated in FIGS. 4A-4G, a tubular body 150 can be embedded within any layer of the road and in-between any layers of the road. For example, as illustrated in FIG. 4A, in some embodiments, a tubular body 150 can be located between the earth layer 104 and the sub-grade layer 103. In FIG. 4A, for example, the tubular body 150 can have been applied on the earth layer 104, and then the sub-grade layer 103 can have been applied on top of the tubular body 150 on the earth layer 104. For another example, as illustrated in FIG. 4B, in some embodiments, a tubular body 150 can be located within the sub-grade layer 103. In FIG. 4B, for example, the tubular body 150 can have been applied with the sub-grade layer 103, such that it becomes located within the sub-grade layer 103.

For another example, as illustrated in FIG. 4C, a tubular body 150 can be located between the sub-grade layer 103 and the sub-base layer 102. In FIG. 4C, for example, the tubular body 150 can have been applied on the sub-grade layer 103, and then the sub-base layer 102 can have been applied on top of the tubular body 150 on the sub-grade layer 103. For another example, as illustrated in FIG. 4D, a tubular body 150 can be located within the sub-base layer 102. In FIG. 4D, for example, the tubular body 150 can have been applied with the sub-base layer 102, such that it becomes located within the sub-grade layer 103.

For another example, as illustrated in FIG. 4E, a tubular body can be located between the sub-base layer 102 and the base layer 101. In FIG. 4E, for example, the tubular body 150 can have been applied on the sub-base layer 102, and then the base layer 101 can have been applied on top of the tubular body 150 on the sub-base layer 102. For another example, as illustrated in FIGS. 4F and 4G, a tubular body 150 can be located within the base layer 101. In FIGS. 3F and 3G, for example, the tubular body 150 can have been applied with the base layer 101, such that it becomes located within the base layer 101.

In another example, the tubular body 150 can be applied after any of the base layer 101, sub-base layer 102, or sub-grade layer 103 are applied but before the respective layer sets (e.g., fully hardens or fixes) and pushed into the respective layer so that the tubular body 150 becomes embedded in such layer after the respective layer sets. In some cases, as shown, e.g., in FIG. 4G, the tubular body 150 can become embedded in an upper portion of the respective base layer 101, sub-base layer 102, or sub-grade layer 103 (rather than the middle portion of the respective base layer 101, sub-base layer 102, or sub-grade layer 103) when the tubular body 150 is pushed into such layer.

FIG. 5 illustrates a perspective view of a tubular body deployment apparatus according to embodiments of the disclosure. An embodiment of a tubular body deployment apparatus is disclosed in U.S. Pat. No. 10,866,380, which is hereby incorporated by reference herein in its entirety. The tubular body deployment apparatus 500 can include a spool 516 mounted to a chassis 526. The spool 516 can hold a predetermined length of tubular body 150 such as optical fiber or communication line. As illustrated, the tubular body 150 can be wound around the spool 516. The tubular body 150 can unwind from spool 516 at a rate commensurate with the apparatus speed in the direction of travel 530 (i.e., advancing direction). The tubular body 150 can pass through the bare communication line guide 514 before the tubular body 150 is placed directly on or in the respective layer. The communication line guide 514 can be mounted to the chassis 526. The communication line guide 514 can be a ring, tube, or similar structure to guide the application of the tubular body 150 on or in the respective layer.

In some embodiments, the tubular body deployment apparatus 500 can include a smoothing apparatus 524 as shown in FIG. 5. In other embodiments, the smoothing apparatus 524 can be omitted. For example, an embodiment of a tubular body deployment apparatus without a smoothing apparatus is disclosed in U.S. Pat. No. 9,588,315, which is hereby incorporated by reference herein in its entirety. Other examples of a tubular body deployment apparatus are disclosed in International Patent Publication No. WO 2022/010553, which is also hereby incorporated by reference herein in its entirety.

In some embodiments, a tubular body deployment apparatus 500 can be used to deploy a tubular body 150 onto the top surface of a layer of road before a subsequent layer is applied on top. For example, the tubular body 150 can be deployed onto the top surface of the sub-base layer 102 by the tubular body deployment apparatus 500 before the base layer 101 is laid.

In other embodiments, a tubular body 150 (e.g., a communication line, a fiber optic cable, an electrical conductor)) can be deployed onto the top surface of a layer of road by the tubular body deployment apparatus 500 and then pushed into (“smushed into”) that layer using, for example, a roller machine. For example, the tubular body 150 can be deployed onto the top surface of the base layer 101 and smushed into the base layer 101 when the roller machine compacts the base layer 101. As one of ordinary skill in the art will appreciate, in order to push the tubular body 150 into a layer, the layer may be capable of receiving the tubular body 150. For example, if the layer comprises asphalt or concrete, the asphalt or concrete may not have cured yet. For another example, if the layer includes gravel, the gravel may not be compacted so densely that it cannot receive the tubular body 150. Optionally, a subsequent layer can be laid on top of the layer that the tubular body has been pushed in to, for example, when the tubular body 150 is pushed into the sub-base layer 102 a base layer 101 can be laid on top.

In addition to the embodiments discussed above, when repaving an existing road, the tubular body 150 can be deployed after the old road is milled and before the new base layer is laid. Further, when adding a subsequent base layer to an existing road, the tubular body 150 can be laid on top of the old base layer before the new base layer is laid or it can be laid on top of and pushed into the new base layer.

In some embodiments, a tubular body 150 can be deployed while performing a step of the road forming process. For example, the tubular body 150 can be deployed while laying or compacting the sub-grade layer 103, sub-base layer 102, or base layers 101. For example, road-building equipment can include a tubular body deployment apparatus 400 to deploy the tubular body 150 while performing other roadbuilding steps. For example, as shown in FIG. 6, a roller machine 600 can be equipped with a tubular body deployment apparatus 500 to deploy the tubular body 150 in front of the roller machine 600 so that the roller machine 600 deploys the tubular body 150 while applying its compacting force to roll, smooth, and/or set the layer. The roller machine 600 can thereby apply the tubular body 150, push it into the layer, and compact the layer in one continuous process.

For another example, as shown in FIG. 7, an asphalt paver machine 700 can be equipped with a tubular body deployment apparatus 500 to deploy a tubular body 150 while laying asphalt in front of the asphalt paver machine 700 so that the asphalt paver machine 700 deploys the tubular body 150 and lays asphalt with the tubular body 150 and/or on top of the tubular body 150. The asphalt paver machine 700 merely provides an example of one type of machine that can form a layer of a paved surface. Any type of paver machine or material-depositing machine that is used to form any layer of a paved surface could be equipped, similar to the example shown in FIG. 7, to include a tubular body deployment apparatus 500 to deploy the tubular body 150 simultaneously with, or in conjunction to, forming the layer.

Although the foregoing embodiments describe a tubular body deployment apparatus 500 attached to a roller machine 600 and an asphalt paver machine 700, the disclosed subject matter is not so limited. Instead, as one of ordinary skill in the art will appreciate, the deployment system can be attached to any piece of equipment used for road building, including, for example, a dump truck configured to store and dump one of asphalt and concrete, a miller configured to destroy a layer of an existing road, a sweeper configured to remove debris from a first surface, or a piece of equipment including a nozzle configured to distribute tack coat onto a surface.

While various exemplary embodiments of the disclosed systems, methods, and apparatuses for forming a road with an embedded tubular body have been described above, it should be understood that these exemplary embodiments have been presented for purposes of example only, and are not limitations. The exemplary embodiments are not exhaustive and do not limit the disclosure to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing of the disclosure, without departing from the breadth or scope.

Claims

1. A method of building a surface comprising an embedded tubular body, the method comprising: applying a first layer of a first material to a first surface; andapplying a tubular body at one of: a top surface of the first layer, within the first layer, and a top surface of the first surface.

2. The method of claim 1, wherein the first material comprises gravel and the first surface comprises earth.

3. The method of claim 1, wherein the first material comprises asphalt and the first surface comprises a gravel layer or an asphalt layer.

4. The method of claim 1, wherein the first material comprises concrete and the first surface comprises a gravel layer.

5. The method of claim 1, wherein applying a tubular body at a top surface of one of the first layer and the first surface comprises: applying the tubular body onto the top surface of the first surface using an apparatus that moves along the top surface of the first surface while the tubular body is being applied along the top surface of the first surface, the tubular body possessing a. bottom face and a top face, the bottom face contacting the top surface of the first surface and the top face being above the top surface of the first surface.

6. The method of claim 1, wherein applying a tubular body at a top surface of one of the first layer and the first surface comprises: applying the tubular body onto the top surface of the first layer using an apparatus that moves along the top surface of the first layer while the tubular body is being applied along the top surface of the first layer, the tubular body possessing a bottom face and a top face, the bottom face contacting the top surface of the first layer and the top face being above the top surface of the first layer.

7. The method of claim 6, further comprising: in response applying the tubular body onto the top surface of the first layer, compacting the first layer.

8. The method of claim 7, further comprising using the apparatus to compact the first layer.

9. The method of claim 1, wherein applying a tubular body at a top surface of one of the first layer and the first surface comprises unspooling a tubular body spool.

10. The method of claim 1, further comprising: removing a second surface to reveal the first surface underneath.

11. An apparatus for building a surface comprising an embedded tubular body, the apparatus comprising: a main body moveable in an advancing direction, the main body possessing a forward end and a read end,a plurality of rotatable bodies that contact the surface when the main body moves in the advancing direction, the plurality of rotatable bodies supporting the main body, the plurality of rotatable bodies configured to contact the surface at a plurality of respective contact points on the surface;a tubular body holder configured to deploy a tubular body onto the surface, the tubular body holder being mounted on the main body, the tubular body configured to be deployed by the tubular body holder to contact the surface at a line contact point; and a road building element configured to perform a step to build the surface.

12. The apparatus according to claim 11, wherein the tubular body holder and the rotatable bodies are configured such that the line contact point is coplanar with the plurality of respective contact points on the rotatable bodies.

13. The apparatus of claim 11, wherein the rotatable bodies comprise a plurality of wheels, the plurality of wheels rotating when the main body moves in the advancing direction.

14. The apparatus of claim 11, wherein the tubular body holder comprises a rotatable spool that rotates to deploy the tubular body onto the surface.

15. The apparatus of claim 14, further comprising a line guide connected to the forward end of the main body, the line guide defining a hole, wherein the tubular body passes through the hole of the line guide before the tubular body contacts the surface.

16. The apparatus of claim 15, wherein the road building element comprises at least one of a roller configured to compact a first layer to a first surface or a dump truck configured to store and dump one of asphalt and concrete, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface ahead of the road building element as the main body advances.

17. The apparatus of claim 11, wherein the road building element comprises a nozzle configured to distribute tack coat onto a first surface.

18. The apparatus of claim 11, wherein the road building element is a miller configured to destroy a layer of an existing road, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface behind the road building element as the main body advances.

19. The apparatus of claim 11, wherein the road building element is a sweeper configured to remove debris from a first surface, and wherein the tubular body holder is configured to deploy the tubular body to contact the surface behind the road building element as the main body advances.

20. A system for embedding a tubular body during a method of building a man-made surface, the system comprising: a tubular body holder configured to deploy the tubular body onto a layer of the man-made surface, the tubular body holder being configured to be mounted onto a vehicle configured to perform a step to build the man-made surface, the tubular body configured to be deployed by the tubular body holder to contact the man-made surface at a line contact point, the tubular body holder comprising a rotatable spool that rotates to deploy the tubular body onto the man-made surface as the vehicle advances.