MULTIPLE GATES FOR DYNAMIC PAVING

TECHNICAL FIELD

The present disclosure relates generally to paving systems, and more specifically to aggregate material paving systems.

BACKGROUND

Aggregate materials, such as asphalt and concrete, are commonly used to build and repair roads, parking lots, and other areas where a smooth durable surface is desired. Asphalt concrete (often abbreviated as “asphalt”) may include an aggregate, additives, and a binding material, usually having a bituminous binder.

Smooth road surfaces improve ride quality and reduce surface water collection areas. Compacted asphalt is more durable and has a higher load carrying capacity than initially deposited and spread asphalt because the process of compacting the asphalt removes air spaces contained within the aggregate and binder mix. In general, as air is removed, asphalt density increases and increasing the compacted asphalt density (typically described as a percentage maximum theoretical density) improves the longevity and load carrying capacity of a road. As an example, many road projects have a target density ranging between 93% and 96%.

However, asphalt does not behave as a free-flowing fluid because the aggregate will extrude into nearby contours but will not free-flow more than a few centimeters without direct agitation. Moreover, when working on asphalt, the compression and extrusion forces produced under a screed and/or compactor are not enough to homogenize the density of the asphalt across an entire width of the screed or compactor. As an example, compaction analysis typically shows that particles are mostly restrained in a horizontal plane such that the compaction may be approximated as only having a vertical movement. As a result, this generally simplifies the required lift height and compaction estimates at the job site because mass is conserved, where the relationship for mass is described by mass=(density)(volume), which results in the following ratio (density₁) (volume₁)=(density₂)(volume₂) because mass is conserved. By utilizing this relationship, when the vertical dimension, or height, of the asphalt is the only changing dimension, the ratio may be rewritten as (density₁)(height₁)=(density₂)(height₂).

As an example, delivered asphalt poured from a dump truck can have a relative density as low as 60%; and utilizing this type of asphalt when paving and compacting over an uneven sub-base, or a sub-base having localized irregularities, can result in bridging, where the asphalt that is compacted over these types of raised sub-base irregularities can quickly reach a high density and hold the weight of the screed and compactor as if the asphalt were a solid material. As a result, this generally prevents consistent asphalt compaction over lower surface irregularities. For example, an evenly spread top surface of asphalt spread over an uneven sub-base with approximately 0.5-inch peaks and approximately 0.5-inch pits, a nominal starting lift height of approximately 2.0 inches, and with the asphalt material delivered at approximately 65% relative density may start with a minimum lift of approximately 1.5 inches, a nominal lift of approximately 2 inches, and a maximum lift of approximately 2.5 inches. Compaction will likely stop when the minimum areas reach a high relative density, for example 97%. In this example, the new minimum height may be determined as

$65 % \times \frac{1.5 inches}{97 %} ≅ 1 inch$

or an 0.5-inch overall height reduction. The relative density of the asphalt material over the nominal height areas may be determined as

$65 % \times \frac{2. inches}{1.5 inches} ≅ 87 % .$

The relative density in material over the localized pits may be

$65 % \times \frac{2.5 inches}{2. inches} ≅ 81 % .$

In this bridging example, the highly compacted asphalt material over peaks supports the compacting surface, resulting in areas with relative compaction as low as 81%.

Generally, the uncompacted surface, or starting height, can be directly viewed exiting some trench paver designs, but is usually a flow stagnation plane which intersects the invisible material head stagnation line as it contacts the front edge of the screed. Material below this stagnation plane will generally compact and pass under the screed, while material above will usually slowly circulate above the stagnation plane.

As a result, grading, milling, and otherwise preparing sub-base surfaces requires significant effort and equipment investment. As an example, when repairing a road, it is common practice to mill a trench at least 8 feet wide (a typical minimum paving width) even if only repairing a 2 foot wide defect because this additional is generally required to maintain consistent compaction from the initially deposited material through the entire paving process to the target density while also trying to make the fully compacted repaired surface flush with the existing road surface at the edge of the repaired section. Therefore, there is a need for a system and method to address these issues.

SUMMARY

A dynamic paving material paver multiple gates for dynamic paving in accordance with the present disclosure is disclosed. The dynamic paving material paver may comprise: a material distribution device; a material leveling device; at least one actuator; and a plurality of gates configured to distribute a paving material on a sub-base via the material leveling device, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct a flow of the paving material received from the material distribution device, and located proximate to, and ahead of, the material leveling device in a direction of the flow of paving material from the material distribution device.

Also disclosed is a method for dynamically paying a sub-base with a dynamic paving material paver. The method may comprise: receiving, via a material distribution device, a flow of a paving material for paving the sub-base; partially obstructing the flow of the paving material from the material distribution device with a plurality of gates located proximate to, and ahead of, the material leveling device in a direction of the flow of the paving material from the material distribution device; and applying the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

Additionally disclosed is another example of a dynamic paving material paver. The dynamic paving material paver may comprise: a material distribution device configured to receive and distribute a flow of a paving material for paving a sub-base; at least one actuator; a plurality of gates located proximate to, and ahead of, the material leveling device in a direction of the flow of the paving material from the material distribution device and configured to distribute the paving material on the sub-base; at least one memory; and at least one processor in signal communication with the material leveling device, the at least one actuator, and at least one memory, wherein the at least one processor is configured to: receive, via the material distribution device, the flow of the paving material; partially obstruct the flow of the paving material from the material distribution device with the plurality of gates utilizing the at least one actuator; and applying the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

Further disclose is a dynamic paving material trench paver. The paving material trench paver may comprise: a pair of side walls, where each side wall has a skid at a bottom of the side wall; a rear side wall attached to the pair of side walls at an upper portion of each side wall; a strike-off plate attached to the pair of side walls and the rear side wall at a lower portion of each of the side walls and a lower portion of the rear side wall, wherein a combined height of the strike-off plate and rear side wall is less than a height of each of the side walls and a bottom of the strike-off plate is located above a bottom of the pair of side walls; an at least one actuator; and a plurality of gates attached to the bottom of the strike-off plate and configured to distribute a flow of a paving material on a sub-base, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct the flow of the paving material from the material distribution device, and located proximate to, and ahead of, a material leveling device in a direction of the flow of paving material from the material distribution device.

The scope of the present disclosure is defined by the claims, which are incorporated into this section by reference. A more complete understanding of embodiments of the invention will be afforded to those skilled in the art, as well as a realization of additional advantages thereof, by a consideration of the following detailed description of one or more embodiments. Reference will be made to the appended sheets of drawings that will first be described briefly.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the disclosure and their advantages can be better understood with reference to the following drawings and the detailed description that follows. It should be appreciated that like reference numerals are used to identify like elements illustrated in one or more of the figures, wherein showings therein are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure.

FIG. 1 is a top view of an example of an implementation of a typical self-propelled asphalt paver.

FIG. 2 is a side-view of the asphalt paver shown in FIG. 1 receiving asphalt from a truck.

FIG. 3 is a side-view of an example of an implementation of an asphalt paver with multiple gates and compaction elements tractor mounted for dynamic paving in accordance with the present disclosure.

FIG. 4 is a side-view of an example of another implementation of a tractor mounted asphalt paver with multiple gates and compaction elements tow-arm mounted for dynamic paving in accordance with the present disclosure.

FIG. 5 is a side-view of yet another implementation of a tractor mounted asphalt paver with multiple gates and compaction elements screed mounted for dynamic paving in accordance with the present disclosure.

FIG. 6 is a cross-section view of an example of an implementation of a trench paver.

FIG. 7 is an isometric view of the trench paver shown in FIG. 6.

FIG. 8 is a side-section view of the trench paver with vertical gates in accordance with the present disclosure.

FIG. 9 is a side-section view of multiple gates aligned with a rearward pitch angle in accordance with the present disclosure.

FIG. 10 is a side-section view of multiple gates aligned with a forward pitch angle in accordance with the present disclosure.

FIG. 11 is a top view of the trench paver with flat facing multiple gates in accordance with the present disclosure.

FIG. 12 is a top view of the trench paver with multiple gates yaw angle slewed toward sides in accordance with the present disclosure.

FIG. 13 is a top view of the trench paver with yaw angle gates slewed toward center in accordance with the present disclosure.

FIG. 14 is a side view of the trench paver with multiple gates rotating around partially enclosed auger in accordance with the present disclosure.

FIG. 15 is a front view of the trench paver with gates aligned with non-vertical roll angle in accordance with the present disclosure.

FIG. 16 is a rear-view of an example of an implementation of actuators controlling gate position of the asphalt paver in accordance with the present disclosure.

FIG. 17 is a close-up view of the actuators shown in FIG. 16 in accordance with the present disclosure.

FIG. 18A is a top view of an example of an implementation of a conveyor distribution system with diversion blades in accordance with the present disclosure.

FIG. 18B is a rear view of the conveyor distribution system with diversion blades shown in FIG. 18A in accordance with the present disclosure.

FIG. 19 is block diagram of an example of an implementation of a secondary gate mounted on the main gate in accordance with the present disclosure.

FIG. 20 is a diagram of example gate cross sections configured for material to flow from right to left in accordance with the present disclosure.

FIG. 21 is a top-perspective view of an example of surface irregularities and bridging on pavement.

FIG. 22 is functional block diagram of an example of paving over surface irregularities with bridging on pavement.

FIG. 23 is a functional block diagram of an example of dynamically paving over surface irregularities without bridging in accordance with the present disclosure.

FIG. 24 is a functional block diagram of an example of dynamic surface deposited over the surface irregularities to avoid bridging in accordance with the present disclosure.

FIG. 25 is a functional block diagram of an example of a unit volume of asphalt and compaction.

FIG. 26 is a functional block diagram of an example of an implementation of a dynamic asphalt paver with multiple gates and compaction elements in accordance with the present disclosure.

FIG. 27 is a flowchart diagram of a method for dynamically paving with the dynamic asphalt paver with multiple gates and compaction elements, shown in FIGS. 1-5 and 26, in accordance with the present disclosure.

DETAILED DESCRIPTION

In accordance with various embodiments of the present disclosure, systems and methods for dynamically paving structures with aggregate materials as disclosed.

Structures such as, for example, roadways, parking lots, and other areas where a smooth durable surface is desired are commonly paved with aggregate materials, such as asphalt and concrete, can develop ruts and potholes. Asphalt concrete (herein abbreviated and referred to simply as “asphalt”) may include an aggregate, additives, and a binding material, usually having a bituminous binder. The features of these types of structures sometimes require that an asphalt surface be removed and replaced. It is desirable to have a system and method which adapts the uncompacted surface height of the asphalt according to the sub-base contour below that surface. This will reduce or eliminate bridging and allow a consistent compacted density regardless of the sub-base irregularities. In this disclosure, the sub-base refers to a layer of aggregate material such, for example, gravel, crushed stone, or sand that is placed on the ground soil (generally referred to as sub-grade) before the asphalt bases in installed on the sub-base.

Existing asphalt paying systems adjust paved lift height for variations in sub-base (i.e., a layer of gravel that is placed on top of subgrade—i.e., the ground) height that span the entire width of the paving pass. Most of these systems adjust the tow point height or screed angle of attack to create a momentary increase in paved depth. While this may work for the full width variations, it is not generally effective over localized irregularities.

The environmental impact of these known roadway resurfacing techniques is significant because the old used asphalt must be reprocessed or disposed of and new asphalt is petroleum based and energy intensive to produce. Both of these actions are a significant source of CO₂and it has been estimated that 90 million tons of asphalt has been milled and reprocessed in the United States each year, and that 0.5 metric tons CO₂are released per ton of fresh asphalt paved.

The techniques discussed herein for dynamically paving roads with asphalt address these issues by discussing a dynamic paving material paver with multiple gates for dynamic paving (herein referred to as a “dynamic asphalt paver” and abbreviated as “DAP”). Also discussed herein is dynamic paving material trench paver (herein referred to as a “trench paver”).

As an example, the DAP may be configured to deposit different amounts material, e.g. asphalt, responsive to variations in a roadway surface. For example, the DAP may be configured to deposit more asphalt over the location of a pothole or a rut in a roadway that may then be compacted by traditional means. These techniques are then utilized to significantly reduce the amount of topcoat of the roadway that should be removed prior to deposition of a new topcoat.

For example, traditional means for repairing a crack or tire rut in a roadway would typically involve milling 8-foot-wide sections of the roadway resulting in the removal of large sections of undamaged material in addition to the specific damaged material immediately surrounding the crack or tire rut. The discussed techniques herein reduce both the amount of used asphalt that should be disposed of and the amount of new asphalt that should be used in resurfacing the damaged roadways.

A dynamic paving material paver multiple gates for dynamic paving in accordance with the present disclosure is disclosed. The dynamic paving material paver may comprise: a material distribution device; at least one actuator; and plurality of gates configured to distribute a paving material on a sub-base, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct a flow of the paving material from the material distribution device, and located proximate to, and ahead of, the material leveling device in a direction of the flow of paving material from the material distribution device.

Additionally disclosed is another example of a dynamic paving material paver. The dynamic paving material paver may comprise: a material distribution device configured to receive and distribute a flow of a paving material for paving a sub-base; at least one actuator; a plurality of gates located proximate to, and ahead of, the material leveling device in a direction of the flow of the paving material from the material distribution device and configured to distribute the paving material on the sub-base; at least one memory; and at least one processor in signal communication with the material distribution device, the at least one actuator, and at least one memory, wherein the at least one processor is configured to: receive, via the material distribution device, the flow of the paving material; partially obstruct the flow of the paving material from the material distribution device with the plurality of gates utilizing the at least one actuator; and applying the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

As another example, the DAP may include multiple gates within the DAP. The gates may form part of the back wall of the DAP and may be followed by compacting devices and screed plates. In some examples, the DAP may not have compacting devices or screeds. In this case, the uneven, uncompacted surface is visible at the exit from the DAP prior to compaction using traditional compaction machines.

Another example includes a smaller gate mounted on one or more of the multiple gates for dynamic paving. This smaller gate meters a smaller quantity of asphalt than the main gate and can reduce power required to move one of the plurality of main gates for small adjustments.

Conveyor and blade asphalt distribution systems are also disclosed herein. One common apparatus to distribute asphalt longitudinally includes a pair of augers, one for material to the right of the machine and one for material to the left of the machine. The augers are usually raised a few inches above the ground and push material over this deposited height. This disclosure identifies an apparatus using a pair of conveyors with a plurality of diversion plates which deposit material in controlled quantities before the screed main surface, before multiple gates, before a pre-compacting device, or before a combination of these items. Use of a conveyor reduces excess material deposited on the ground and simplifies end of pass cleanup.

FIG. 1 is a top-view of an example of an implementation of a typical self-propelled asphalt paver 100 that may include a hopper 102, a conveyor 104, a lateral distribution device 106 such as, for example, an at least one auger 108, and a screed 110. In this example, the hopper 102 may include an open top to receive fresh asphalt, temporarily hold the asphalt, and dispense the asphalt, via the conveyor 104, through an opening in the back wall 112 of the hopper 102. The asphalt is moved by the conveyor 104 from the hopper 102 to a material distribution device. In this example, the hopper 102 may be disposed towards the front of the asphalt paver 100, and an operator controls the asphalt paver 100 from a control station 114 behind the hopper 102. Moreover, in this example, the screed 110 may combine the functions a material leveling device, a surface leveling device, a surface smoothing device, and a compacting device.

In an example of operation, the lateral distribution device 106 moves asphalt laterally across the area of a surface to be paved where the asphalt material is placed in front of screed 110. The asphalt collects in front of screed 110 and is further distributed across the width of the screed 110 as collected piles of asphalt in front of the screed 110 fall to the sides and also recirculate forward. The asphalt passing under the screed 110 is partially compacted and the top surface of the asphalt exiting the screed 110 is smoothed. In this example, a left screed extension 116 and right screed extension 118 may be configured to allow the screed 110, left screed extension 116, and right screed extension 118 to vary a paved width along the surface to be paved. The asphalt paver 100 may be configured to travel in a direction 120 and the lateral distribution device 106 typically moves the asphalt along a direction approximately normal to the direction 120 of travel of the asphalt paver 100 as indicated by arrows 122 and 124.

In this disclosure, the screed 110 may be configured as a free-floating screed that is a leveling device that is configured to spread and smooth out (i.e., “screed”) a paving material (e.g. concrete or asphalt) below it. In general, the screed 110 is configured to be physically connected to a tractor portion of a paving machine (e.g., the asphalt paver 100) via at least one towing arm.

In typical operation, the asphalt is transferred from the hopper 102 at the front of the tractor to the screed 110 via the conveyor 104 and lateral distribution device 106, and the at least one auger 108 spread it across the width of the screed 110. The asphalt then flows out across the width of the screed 110. Adjusting the settings of the screed 110 will change the placement depth and width of the asphalt, as well as the amount of asphalt being placed on the paving surface.

In this example as a free-floating screed, the screed 110 may be physically connected to the tractor portion of the asphalt paver 100 via at least one tow arm. As such, the screed 110 can “float” vertically relative to the asphalt paver 100, which allows the tractor asphalt paver 100 to traverse an uneven ground while the screed 110 floats over the asphalt placed in front of the screed 110.

FIG. 2 is a side-view of the asphalt paver 100 receiving the asphalt 200 from a truck 202 in front of the asphalt paver 100. In this example, the asphalt paver 100 may ride on a drive system 204 that includes, for example, wheels or tracks driven by a motor or engine. The hopper 102 may be configured to hold a volume of asphalt 200 and have an open top to receive fresh asphalt 200 from the truck 202. Additionally, in this example, the screed 110 is shown physically connected to the asphalt paver 100 by the at least one tow arm 206, where the at least one tow arm 206 may be connected to the asphalt paver 100 at an axially rotatable tow point 207 and to the screed 110 at an axially rotatable hinge point. In this example, the screed 110 angle relative to the at least one tow arm 206 may be controlled by an at least one jack screw.

In this example, the asphalt 200 deposited on a sub-base 208 (i.e., the ground) by the lateral distribution device 106 may be in physical contract with the screed 110 at a strike-off plate 210, where the screed 110 strike-off plate 210 has a leading edge 212 that separates the asphalt 200 pushed forward by a front face of screed 110 from the asphalt 200 which passes under the screed 110. The asphalt 214 that is above the leading edge 212 typically builds up along the front face of screed 110 until it can no longer support its own weight and then falls forward where it typically circulates forward and laterally as it mixes with the fresh new asphalt 200 that is supplied by lateral distribution device 106 and at least one auger 108.

Turning to FIG. 3, a side-view is shown of an example of an implementation of a dynamic asphalt paver (DAP) 300 with multiple gates 302 and compaction elements (i.e., a compacting device 304) that is tractor mounted for dynamic paving in accordance with the present disclosure. In this example, the DAP is a dynamic paving material paver that may include a material distribution device; at least one actuator; and a plurality of gates configured to distribute a paving material on a sub-base, where the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct a flow of the paving material from the material distribution device, and located proximate to, and ahead of, the material leveling device in a direction of the flow of paving material from the material distribution device.

The dynamic paving material paver may further comprise a compacting device located proximate to, and behind, the plurality of gates, where the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates. The dynamic paving material paver may also comprise a material leveling device that may include, for example, a screed having a screed surface, where the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base. The dynamic paving material paver may also comprise at least one tow-arm that is configured to attach the screed to the dynamic paving material paver. In this example the compacting device may include at least one compressor disposed between the plurality of gates and the screed surface, the at least one compressor being configured to compress the paving material. The plurality of gates may be configured to act as the at least one compressor. The at least one compressor may include a plurality of compressors and each of the compressors of the plurality of compressor is configured to compress the paving material to a different height. Moreover, the plurality of compressors may be divided into a plurality of compressor segments, where each of the compressor segments may be configured to apply a different force on the paving material or compress the paving material to a different height.

In these examples, each gate of the plurality of gates may be separately height adjustable, independently adjustable in both height and angle, disposed at a different angle relative to each other gate of the plurality of gates, or any combination of thereof.

The dynamic paving material paver may also include a sensor configured to detect a flatness of the paving material to a screed surface of a screed physically coupled to the dynamic paving material paver. The dynamic paving material paver may also include another sensor configured to detect variations in flatness of the sub-base prior to addition of the paving material to the sub-base.

In this example, the material distribution device may be a lateral distribution device (similar to the lateral distribution device 106 shown in FIGS. 1 and 2) that includes a conveyor and at least one auger. In this example, the at least one auger may include at least one rotating auger cover that rotates about the at least one auger. As an example, the at least one rotating auger cover may include a plurality of rotating auger covers, and the plurality of gates may be configured as the plurality of rotating auger covers.

As a further example, the dynamic paving material paver may further include a tractor portion; a compacting device located proximate to, and behind, the plurality of gates, wherein the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates; a screed having a screed surface, wherein the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base; and least one tow-arm that is configured to attach the screed to the tractor portion.

Specifically, in this example, the DAP 300 may include, for example, the multiple gates 302 (i.e., the plurality of gates), a compacting device 304, at least one actuator 306, at least one sensor 308, a gate controller 310, an asphalt lateral distribution device 312, and material leveling device (that may include, for example, a screed 314). The screed 314 may include a screed plate 316 that is configured to smooth and compresses the asphalt 318 as it passes from a leading edge 320 to a trailing edge 322 of the screed plate 316. As discussed previously the asphalt 318 may be accumulated in a hopper 321 that includes a conveyor 323.

In this example, the at least one sensor 308 is shown but it is appreciated that the DAP 300 may not include the at least one sensor 308 because a user may utilize an independently controlled sensor to scan the surface to be paved and the information from that sensor may be proved to the DAP 300 via scanned information which one or more processors of the DAP 300 or a user of the DAP 300 may utilize to pave the surface.

In this example, the multiple gates 302 may be combined with the compacting device 304, where the multiple gates 302 may be, for example, tamper bars set at various heights. Alternatively, the multiple gates 302 may include vibratory plates after the multiple gates 302, a vibratory plate with non-planar contours after the multiple gates 302, rolling compaction after the multiple gates 302, or a combination thereof. Another embodiment, for use in combination with DAP 300, may not include compacting device 304. When used in combination with the screed 314, the compacting device 304 increases asphalt 318 compaction before the asphalt 318 passes under screed 314 and reduces or eliminates material circulation in front of the screed 314.

As another example, the multiple gates 302 and the compacting device 304 may be attached to a tractor part of the DAP 300. The multiple gates 302 may be placed close to the asphalt lateral distribution device 312 to reduce in process asphalt 318. Moreover, the multiple gates 302 may also be placed close to the material leveling device such as the screed 314. Other examples may increase the space between the asphalt lateral distribution device 312, the multiple gates 302, the compacting device 304, and/or the screed 314.

In this example, each gate within the multiple gates 302 may connected to an actuator (of the at least one actuator 306), which can dynamically adjust an individual gate height of each individual gate of the multiple gates 302. The desired gate height may be controlled by the gate controller 310, which may adjust the gate height as the gate travels over irregularities 326 of the sub-base 324 surface to produce the compressed asphalt 327 on the sub-base 324.

In this disclosure, the sub-base 324 is a layer of aggregate material laid on a subgrade (e.g., soil), on which a base course layer is located. The sub-base 324 may often be the main load-bearing layer of a pavement surface and it has the role to spread the load of the surface evenly over the subgrade. As an example, the materials used for the sub-base 324 may be, for example, unbound granular, or cement-bound granular materials such as, for example, crushed stone, crushed slag, crushed concrete, or slate.

The irregularities 326 of the sub-base 324 surface may be identified by the at least one sensor 308, which may be attached to DAP 300. Alternatively, sub-base 324 may be scanned independently and the irregularities 326 of the surface may be identified using one or more sensors attached to an independent ground based machine operating in front of the DAP 300, by an operator carrying a hand-held sensor ahead of DAP 300, by one or more stationary sensors mounted along the paving path, by at least one sensor attached to an aircraft operating in front of the DAP 300, or by a combination of these methods. In this example, the at least one sensor 308 may use the full range of the electromagnet spectrum that includes, for example, the visual spectrum electromagnetic, infrared electromagnetic, ultraviolet electromagnetic; sonic, magnetoresistance; electric resistance; physical contact; or a combination of these means to identify surface irregularities. The at least one actuator 306 may be, for example, a linear electric actuator, hydraulic actuator, pneumatic actuator, or any other device which can dynamically move each gate to a preferred location while DAP 300 is moving.

In an example of operation, the screed 314 may pivot about the tow points 328 until it reaches an equilibrium screed angle and the screed 314 height may be controlled by changing the screed angle relative to the tow-arms 330 using jack screws. As the DAP 300 continues to move forward, the screed 314 may pivot about the tow points 328 until a new equilibrium is reached. While moving to the new equilibrium, both the screed height and the screed angle may change.

FIG. 4 is a side-view of an example of another implementation of a DAP 400 with the multiple gates 302 and the compaction elements (i.e., compacting device 402) tow-arm mounted in accordance with the present disclosure. In this example, the DAP 400 may be attached to a tractor via a tow arm as compared to FIG. 3, where the DAP 300 is attached to the tractor.

In this example, the multiple gates 302 may be combined with the compacting device 402, such as tamper bars set at various heights. In alternative embodiments, not shown, the DAP 400 may include vibratory plates after the multiple gates 302, a vibrating plate with non-planer contours after the multiple gates 302, a rolling compaction after the multiple gates 302, or a combination thereof.

In this example, the multiple gates 302 and the compacting device 402 may be coupled to a pair of tow-arms 330. The multiple gates 302 may be placed close to the asphalt 318 lateral distribution device 312 to reduce the amount of in process asphalt 318 in front of the material leveling device (i.e., the screed 314). Other embodiments may increase the space between asphalt lateral distribution device 312, the multiple gates 302, and the compacting device 402.

FIG. 5 is a side-view of an example of yet another implementation of a tractor mounted DAP 500 with the multiple gates 302 and a compacting device 502 that is screed 314 mounted in accordance with the present disclosure. In this example, the multiple gates 302 may be combined with the compacting device 502, such as, for example, tamper bars set at various heights. In alternative embodiments, not shown, the DAP 500 may include vibratory plates after the multiple gates 302, a vibrating plate with non-planer contours after the multiple gates 302, a rolling compaction after the multiple gates 302, or a combination thereof.

In this example, the multiple gates 302 and the compacting device 502 may be attached to the screed 314, where the multiple gates 302 are close to the screed 314. In some embodiments, the multiple gates 302 and the compacting device 502 may be sufficiently close to the screed 314 such that a screed strike-off plate 504 may be removed from the example design. Alternatively, the multiple gates 302 may be placed close to asphalt lateral distribution device 312 and/or material leveling device (i.e., the screed 314), to reduce the amount of in process asphalt 318. Other embodiments may increase a space between asphalt lateral distribution device 312, the multiple gates 302, the compacting device 502, and/or material leveling device, but maintain some space between compacting device 502 and the screed strike-off plate 504. The multiple gates 302 for dynamic paving may also be attached to screed extensions (e.g., left screed extension 116 and right screed extension 118 shown in relation to FIG. 1) in a manner similar to the multiple gates 302 attached to screed 314.

Turning to FIG. 6, a cross-section view of an example of an implementation of a trench paver 600. In this example, the asphalt 318 (not shown) may be placed on the sub-base 602 in front of trench paver 600, which collects the asphalt 318 between the trench paver 600 side walls 604. In this example, a rear wall 606 collects the asphalt 318 and distributes it across the width of trench paver 600. A strike-off plate 608, attached to the rear wall 606, creates an opening 610 between sub-base 602, side walls 604, and the strike-off plate 608. The asphalt 318 passing through this opening 610 is typically compacted by a separate machine. In some cases, a trench paver screed 612 may be attached to the trench paver 600. The trench paver screed 612 may partially compact the asphalt 318 and smooth the top surface of asphalt 318 on the sub-base 602.

In this example, if the trench paver screed 612 is included as part of the trench paver 600, trench paver screed 612 may be attached with height adjusting screws. In some cases, the trench paver screed 612 may be attached to the trench paver 600 with the pair of tow-arms 330. The trench paver 600 in this example may not have a traction system and may utilize a coupling plate 614 that attaches the trench paver 600 to, for example, a powered machine, such as a tractor, skid-steer loader, or wheeled loader. The powered machine may push trench paver 600, which slides on the lower edges of side walls 604 with, for example, skids 616. In an example of operation, the trench paver 600 may be pushed in the direction of travel 618.

FIG. 7 is an isometric view of the trench paver 600. In this view, the strike-off plate 608 may be set at a desired paved lift above the sub-base 602. As an example, the strike-off plate 608 height may be fixed before a paving run. Some embodiments may allow dynamic adjustments to the entire strike-off plate 608 height, but may not allow differential height adjustments across the width of the rear wall.

Turning to the additional embodiments shown in FIGS. 8-15 multiple gates 800 for dynamic paving with an updated trench paver 802 may be utilized to replace the previous trench paver 700 strike-off plate 608. For simplicity and ease of illustration, the multiple gates 800 are shown as perpendicular to a direction of travel 804 of the trench paver 802. In these examples, the multiple gates 800 orientation angles may be fixed or rotatably adjustable.

Specifically, FIG. 8 is a side-section view of the trench paver 802 with vertical gates in accordance with the present disclosure. FIG. 9 is a side-section view of multiple gates aligned with a rearward pitch angle in accordance with the present disclosure. FIG. 10 is a side-section view of multiple gates aligned with a forward pitch angle in accordance with the present disclosure. FIG. 11 is a top view of the trench paver with flat facing multiple gates in accordance with the present disclosure. FIG. 12 is a top view of the trench paver with multiple gates yaw angle slewed toward sides in accordance with the present disclosure. FIG. 13 is a top view of the trench paver with yaw angle gates slewed toward center in accordance with the present disclosure.

In this examples, a pitch angle 806 (noted as angle “B” in FIGS. 8-10) may vary, for example, between approximately 30 and approximately 160 degrees. As another example, the rearward sloping multiple gates 800 with β between approximately 95 and approximately 160 degrees, may increase the asphalt 318 circulation rate, reduce the overall multiple gate design height, and increase gate vertical position sensitivity relative to an at least one sensed actuator 306 position. The forward sloping multiple gates 800 with ß between approximately 30 and approximately 85 degrees, may partially compact the asphalt 318, may reduce the overall multiple gate 800 design height, and increase multiple gate 800 vertical position sensitivity relative to sensed actuator 306 position. In these embodiments, the multiple gates 800 may move parallel to a gate front face, as indicated by a gate movement arrow 808.

A yaw angle 1100 (noted as angle “o” in FIGS. 11-13) may vary for the trench paver 802 between, for example, approximately 30 and approximately 160 degrees. The rearward slewing multiple gates 800, as shown in FIG. 12 with @ between, for example, approximately 95 and approximately 160 degrees, may improve the asphalt 318 flow from the DAP 300 centerline or trench paver 802 centerline to the outer edges. Outward moving asphalt 318 flow more evenly distributes the asphalt 318 across the entire width of screed 314 and screed extensions 116 and 118. The forward slewing multiple gates 800, as shown in FIG. 13, with φ between, for example, approximately 30 and approximately 85 degrees, may improve the asphalt 318 flow from trench paver side walls 604 or the DAP 300 outer edges to the trench paver 802 or screed 314 centerline. Center moving asphalt 318 may reduce the likelihood that asphalt 318 may stagnate and cool next to the trench paver side walls 604. In these embodiments, multiple gates 800 movement is perpendicular to the view plane.

In these examples, the gate width 1102 (noted as “W” in FIGS. 11-13) may be between, for example, approximately 50 millimeters (mm) and approximately 400 mm. The example embodiments shown in this disclosure may either maintain an equal gate width 1102 for each disclosed embodiment or have unequal gate widths on the same machine.

Turning to FIG. 14, a side view of the trench paver 1400 with multiple gates 1402 rotating around a partially enclosed auger 1404 is shown in accordance with the present disclosure. In this example, the multiple gates 1402 for dynamic paving may be cylindrical in shape and rotate about the asphalt lateral distribution device 312. In this embodiment, the asphalt lateral distribution device 312 may be partially enclosed by a distribution enclosure 1406. The asphalt 318 may move from the conveyor 323, typically located near the center of the DAP 300, to an opening in distribution enclosure 1406. The asphalt 318 may then be distributed longitudinally until passing through one or more gate openings. Each of the multiple gates 1402 may be individually rotated as indicated by gate travel 1408 to a controlled gate edge height.

Referring back to FIGS. 3-5, it is appreciated by those of ordinary skill in the art that same technique may be utilized for DAPs 300, 400, and 500, where the multiple gates 302 and asphalt lateral distribution device 312 may be combined such that the asphalt lateral distribution device 312 is a material distribution device that includes a least one auger (e.g., auger 108) and the at least one auger includes at least one rotating auger cover that rotates about the at least one auger. In this example, the at least one rotating auger cover may include a plurality of rotating auger covers, and multiple gates 302 may be configured as the plurality of rotating auger covers.

In general FIGS. 6-13 and 15-17, a dynamic paving material trench paver is shown and described. In general, the dynamic paving material trench paver may comprise a pair of side walls, where each side wall has a skid at a bottom of the side wall; a rear side wall attached to the pair of side walls at an upper portion of each side wall; a strike-off plate attached to the pair of side walls and the rear side wall at a lower portion of each of the side walls and a lower portion of the rear side wall, where a combined height of the strike-off plate and rear side wall is less than a height of each of the side walls and a bottom of the strike-off plate is located above a bottom of the pair of side walls; an at least one actuator; and a plurality of gates attached to the bottom of the strike-off plate and configured to distribute a flow of a paving material on a sub-base. In this example, the plurality of gates may be mechanically coupled to the at least one actuator, configured to partially obstruct the flow of the paving material from the material distribution device, and located proximate to, and ahead of, a material leveling device in a direction of the flow of paving material from the material distribution device.

The dynamic paving material trench paver may further include a compacting device located proximate to, and behind, the plurality of gates, where the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates; and/or a screed having a screed surface, where the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base.

In these examples, each gate of the plurality of gates may be configured to be separately height adjustable, independently adjustable in both height and angle, disposed at a different angle relative to each other gate of the plurality of gates, or any combination thereof.

Turning to FIG. 15, a front view of the trench paver 1400 with multiple gates 1402 aligned with a non-vertical roll angle 1500 is shown in accordance with the present disclosure. In this example, the roll angle 1500 (noted as angle “A”) may vary, for example, between approximately 30 and approximately 160 degrees. In this example, the multiple gates 1402 may be tilted to the left, with a roll angle, for example, between approximately 30 and approximately 85 degrees, allowing the rightmost gates to contact asphalt 318 with a minimum of overhead structure. Likewise, the multiple gates 800 may be tilted to the right, with a roll angle, for example, between approximately between approximately 95 and approximately 160 degrees, allows the leftmost gates to contact asphalt 318 with a minimum of overhead structure. In these embodiments, multiple gates 800 may move parallel to the gate front face, as indicated by gate movement arrow 808.

In these examples, the embodiments of the present disclosure may combine any combination of roll, pitch, and yaw.

FIG. 16 is a rear-view of an example of an implementation of actuators controlling gate position of the asphalt trench paver (e.g., trench paver 1400) in accordance with the present disclosure. FIG. 17 is a close-up view of the actuators shown in FIG. 16 in accordance with the present disclosure. In this example, FIGS. 16 and 17 show the multiple gate 1402 mounting and control in more detail. FIG. 16 is a trench paver 1400 rear view with right hand gates open and right-hand gate actuators 1600 disassembled from a gate support structure 1602. In this example, each individual gate height is independently controlled by actuator 1600, which may have an actuator position sensor 1604. This view of the embodiment also shows left-hand gates 1402 located below trench paver 1400 skids 616. The actuators 1600 may be connected to the gate support structure 1602 at an actuator 1600 to the frame mounting point 1610. Each of the individual gates of the multiple gate 1402 are also attached to the gate support structure 1602, which may be fixably or rotatably mounted to the trench paver 600. Each actuator 1600 may also be attached to a corresponding gate at the actuator to gate mounting point 1612. In this example, individual gates in multiple gate 1402 can slide in one axis as determined by the orientation of gate support structure 1602. The actuator 1600 may be, for example, an electronic linear actuator, a hydraulic cylinder, a pneumatic cylinder, or any other device with a controllable linear position.

In this example, the right-side gates of multiple gate 800 are shown partially assembled and the actuator 1600 is shown attached to the gate in a raised position; however, actuator 1600 is retracted showing the actuator mounting point 1612 on both the actuator and gate support structure 1602.

In FIG. 17, the actuator 1600 attachment to gate support structure 1602 and to individual gates in multiple gate 800 is shown in more detail. In this example, the gate position can be determined directly from the actuator extension, and position sensor 1604 may be enclosed within the actuator 1520. Other embodiments may use a separate position sensor 1604 that measures each individual gate of multiple gate 800 position relative to gate support structure 1602.

Turning to FIG. 18A, a top view of an example of an implementation of a conveyor distribution system with diversion blades is shown in accordance with the present disclosure. FIG. 18B is a rear view of the conveyor distribution system with diversion blades shown in FIG. 18A in accordance with the present disclosure. In general, FIGS. 18A and 18B show the top and rear view of an example of an implementation of the distribution system in the present disclosure.

FIG. 18A is a top view that shows a single conveyor 1800 which moves asphalt 318 from the hopper 321 to distribution device 1802 in a direction 1804. Other embodiments, shown in FIG. 18B, have two parallel conveyors 1806 and 1808 from the hopper 321 to the distribution device 1802, one feeding the left side distribution and one feeding right side distribution. The distribution device 1802 may comprise the laterally oriented left conveyor 1806, the laterally oriented right conveyor 1808, and multiple dynamic diverter plates 1810 adjustably located over each of left and right conveyors.

The asphalt 318 flow rate through the conveyor distribution device can be more precisely controlled by adjusting conveyor 1806 and 1808 speeds than the material flow through an auger distribution device. The dynamic diverter plates 1810 may adjust position as required to move material from the conveyor to the multiple gates 1402 or screed 314. The material also exits the end of conveyors 1806 and 1808 as a direct feed in front of the material leveling device (i.e., screed extensions 116 and 118), or the multiple gate 1402 attached to screed extensions 116 and 118. In this example, FIG. 18A shows a horizontal diverter plate 1810 movement while FIG. 18B shows a vertical diverter plate 1810 movement. In this example, the horizontal diverter plates and/or vertical diverter plates may act as gates in that the divert and obstruct the flow of paving material from the distribution device 1802 to a material leveling device.

FIG. 19 is block diagram of an example of an implementation of a secondary gate mounted on the multiple gates 1402 in accordance with the present disclosure. FIG. 19 shows another embodiment which includes a secondary gate 1900 that may be mounted on a larger individual gate which is one of the multiple gates 1402. The secondary gate 1900 has actuator 1600 that is mounted to the primary gate. The secondary gate 1900 can reduce the total number of gates required and can adjust the amount of material passing under the primary gate without moving the outer gate corners. The asphalt 318 passing through the gate creates a vertical wall that will slump to an angle, for example, between approximately 45 and approximately 90 degrees, depending on the binder properties, aggregate shape, temperature, vibration, and paver changes in direction. The material passing through the gap created by secondary gate edge 1920 and the edges of gate 1402 adds small amounts to the material passing through the main gate without making multiple main gate adjustments.

Turning to FIG. 20, a diagram of example gate cross sections configured for material to flow from right to left is shown in accordance with the present disclosure. In general, FIG. 20 illustrates a top view of various gate profiles 2000 considered in the present embodiment for individual gates in multiple gates for dynamic paving with DAP 300. The DAP 300 direction of travel 2002 indicates the nominal gate orientation without pitch angle 806, yaw angle 1100, or roll angle 1504 adjustments. The asphalt 318 presses against primary gate faces 2004, builds pressure, and slowly moves perpendicular to the primary gate face 2004 as DAP 300 or trench paver 600 moves forward. Some profiles may also include a secondary face or faces 2006. The asphalt 318 slides along the secondary face 2006 when neighboring gates 1402 are open without significantly changing speed but asphalt 318 may be diverted to a new direction. Some profiles may include arched sections which transition from a primary gate face 2004 to a secondary face 2006.

Some gate profiles contain a vertical sharp edge 2008 or rapid change in profile. The material contacting a gate profile 2000 with a sharp edge 2008 tends to split into material flowing left and right of the sharp edge 2008. Profiles without primary gate face 2004 usually include the sharp edge 2008 and one or more secondary faces 2006 which quickly redirect the asphalt 318 through a neighboring open gate. One example use is for gates near the outer edges of the screed extensions 141 and 142 or trench paver side walls 604. The asphalt 318 is more efficiently pressed into the outermost corner of the paving run. Profiles with sharp edge 2008 may also break apart partially conglomerated asphalt 318 and reduce the impact of asphalt temperature segregation.

The gate profiles with a single primary gate face 2004 or multiple primary gate faces 2004 which are at an obtuse angle to each other leave a trail of the asphalt 318 through open gates which is mostly parallel with paver direction of travel 2002 or trench paver direction of travel. However, as the yaw angle 1100 changes from perpendicular to the direction of travel 2002, the material passes through open gates perpendicular to primary gate face 2004. The multiple gate 1402 designs with yaw angles benefit from a secondary gate face 2006 which redirects the asphalt 318 flow through open gates to be parallel with direction of travel 2002.

Substantially curved, or half-pipe, profiles with two sharp edges 2008 generally accelerate asphalt 318 flow through quickly opening gates while curved profiles without sharp edges 2008 increase the asphalt 318 flow into open neighboring gates.

Turning to FIG. 21, a top-perspective view of an example of surface irregularities and bridging on pavement is shown. FIG. 22 is functional block diagram of an example of paving over surface irregularities with bridging on pavement. FIG. 23 is a functional block diagram of an example of dynamically paving over surface irregularities without bridging in accordance with the present disclosure. FIG. 24 is a functional block diagram of an example of dynamic surface deposited over the surface irregularities to avoid bridging in accordance with the present disclosure.

In general, FIGS. 21-24 illustrate road and paving defects which the present invention corrects. The surface defects, including localized surface irregularities 2100, pavement cracks 2102, and pavement joint separation 2104 can be detected using a sensor 2106 (e.g., may be the at least one sensor 308 of FIG. 3). The surface defects may also be present after paving preparation operations are complete, usually as localized depressions in sub-base 2108. The present invention discloses several multiple gate dynamic paving embodiments which place additional asphalt 2109 over surface irregularities 2100 which extend below the sub-base 2108 surface, and which reduce the quantity of asphalt 2109 over raised surface irregularities 2100. In these figures, the screed 314 and compacting device 304 are moving in the direction of paving 2110. The matching asphalt 2109 deposition with surface irregularities 2100 prevents differential compaction, or regions of reduced density bridged asphalt 2112. In general, bridging is difficult to detect without advanced density measurement devices.

FIG. 22 illustrates known paving practices in areas with surface irregularities or different height trench overlays. The screed 110 may deposit a smooth upper surface of homogeneous partially compacted asphalt 2109 over the irregularities. The compactor 2200 also creates a smooth top surface, which results in bridged asphalt 2202 which is not compacted to the same density as the supporting asphalt surrounding the bridged area.

FIGS. 23 and 24 illustrate paving practices enabled by the present invention. The multiple gates 1402 create a dynamic surface over the irregularities 2100 of the surface, including areas around crack 2102 removal by localized milling and joint separation 2104 removed by localized milling. When combined with compacting device 304, the density of asphalt 2109 exiting the screed 314 is much closer to maximum theoretical density and is homogeneous across the paved width.

FIG. 25 is a functional block diagram of an example of a unit volume of asphalt and compaction. This example illustrates the difference between relative density on the left and maximum theoretical density on the right. A unit volume of asphalt 2500 can be considered to be a mixture of three parts, aggregate displaced volume 2502, binder displaced volume 2504, and air volume 2506. The maximum theoretical density occurs when all air has been removed from the unit volume of asphalt 2500. During compaction, particles of asphalt aggregate typically cannot move laterally. They are either constrained by neighboring asphalt or construction surfaces, such as curbs. The aggregate particles at the edge of unrestrained lifts may partially extrude, however, this movement is negligible within a few centimeters of the unrestrained edge. The mass within the volume of asphalt is the sum of aggregate and binder mass; the mass of air is insignificant. The relative density is defined as partially compacted density divided by maximum theoretical density. The mass in this ratio of two densities is equal; therefore, the ratio can be simplified to

$\frac{{Volume}_{Max}}{{Volume}_{\partial Compaction}} .$

Because the height is the only meaningful change in a compacted unit volume, this can be further simplified to S/H where S is the height of the maximum theoretical density volume and H is the height of the corresponding partially compacted volume.

Turning to FIG. 26, a functional block diagram of an example of an implementation of a DAP 2600 with a plurality of gates 2602 and a compaction device 2604 is shown in accordance with the present disclosure.

In this example, the DAP 2600 may comprise: a material distribution device 2606 (e.g., asphalt lateral distribution device 312) configured to receive and distribute a flow of a paving material 2608 (e.g., asphalt 318) for paving a sub-base (e.g., 324); at least one actuator 2610 (e.g., at least one actuator 306); a plurality of gates located proximate to, and ahead of, the material leveling device (e.g., a screed 2620) in a direction of the flow of the paving material from the material distribution device 2606 and configured to distribute the paving material on the sub-base; at least one memory 2614 (e.g., one or more memories for use by the gate controller 310); and at least one processor 2616 (e.g., one or more processors that are part of the gate controller 310) in signal communication with the material distribution device 2606, the at least one actuator 2610, and at least one memory 2614, where the at least one processor 2616 is configured to: receive, via the material distribution device 2606, the flow of the paving material 2608; partially obstruct the 2612 flow of the paving material from the material distribution device 2612 with the plurality of gates 2602 utilizing the at least one actuator 2610; and applying the paving material, from the flow 2618 of paving material that is not partially obstructed by the plurality of gates 2602, to the sub-base in front of a screed 2620 (e.g., screed 314).

FIG. 27 is a flowchart diagram of a method 2700 for dynamically paving with the dynamic asphalt paver with multiple gates and compaction elements, shown in FIGS. 1-5 and 26, in accordance with the present disclosure. As an example, the method 2700 may comprise: receiving 2702, via a material distribution device, a flow of a paving material for paving the sub-base; partially obstructing 2704 the flow of the paving material from the material distribution device with a plurality of gates located proximate to, and ahead of, the material leveling device in a direction of the flow of the paving material from the material distribution device; and applying 2706 the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

The method 2700 may further comprise compacting, with a compacting device located proximate to, and behind, the plurality of gates, the paving, from the flow of paving material that is not partially obstructed by the plurality of gates, on the sub-base and/or controlling a height of the compacting device relative to a screed surface to produce a flat surface of paving material on the sub-base. The method 2700 may further comprise compressing the paving material with the compressing device that is disposed between the plurality of gates and the screed surface.

In this example, compressing the paving material with the compressing device may include compressing the paving material with the plurality of gates. Additionally, compressing the paving material with the compressing device may include compressing the paving material with a plurality of compressors and each of the compressors of the plurality of compressor compresses the paving material to a different height. Furthermore, compressing paving material with the compressing device may include compressing the paving material with a plurality of compressors and each of the compressors of the plurality of compressor compresses the paving material to a different height.

In this example, receiving the flow of a paving material may include receiving the paving material from a lateral distribution device that may include a conveyor and at least one auger having plurality of rotating auger covers that rotate about the at least one auger, and partially obstructing the flow of the paving material from the material distribution device with a plurality of gates may include partially obstructing the flow of the paving material with the plurality of rotating auger covers.

Items and/or techniques described herein may provide one or more of the following capabilities, as well as other capabilities not mentioned. Other capabilities may be provided and not every implementation according to the disclosure must provide any, let alone all, of the capabilities discussed.

Implementation Examples

Implementation examples are provided in the following numbered clauses.

Clause 1. A dynamic paving material paver comprising: a material distribution device; a material leveling device; at least one actuator; and a plurality of gates configured to distribute a paving material on a sub-base via the material leveling device, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct a flow of the paving material received from the material distribution device, and located proximate to, and ahead of, the material leveling device in a direction of the flow of paving material from the material distribution device.

Clause 2. The dynamic paving material paver of clause 1, wherein the paving material is asphalt.

Clause 3. The dynamic paving material paver of clause 1, wherein the plurality of gates is configured in a chevron pattern.

Clause 4. The dynamic paving material paver of clause 1, further comprising a compacting device located proximate to, and behind, the plurality of gates, wherein the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates.

Clause 5. The dynamic paving material paver of clause 4, wherein the material leveling device includes a screed having a screed surface, wherein the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base.

Clause 6. The dynamic paving material paver of clause 5, further comprising at least one tow-arm that is configured to attach the screed to the dynamic paving material paver.

Clause 7. The dynamic paving material paver of clause 5, wherein the compacting device includes at least one compressor disposed between the plurality of gates and the screed surface, the at least one compressor being configured to compress the paving material.

Clause 8. The dynamic paving material paver of clauses 7, wherein the plurality of gates is configured to act as the at least one compressor.

Clause 9. The dynamic paving material paver of clause 7, wherein the at least one compressor includes a plurality of compressors and each of the compressors of the plurality of compressor is configured to compress the paving material to a different height.

Clause 10. The dynamic paving material paver of clause 9, wherein the plurality of compressors is divided into a plurality of compressor segments, each of the compressor segments is configured to apply a different force on the paving material or compress the paving material to a different height.

Clause 11. The dynamic paving material paver of clause 1, wherein each gate of the plurality of gates is separately height adjustable.

Clause 12. The dynamic paving material paver of clause 1, wherein each gate of the plurality of gates is independently adjustable in both height and angle.

Clause 13. The dynamic paving material paver of clause 12, wherein each gate is disposed at a different angle relative to each other gate of the plurality of gates.

Clause 14. The dynamic paving material paver of clause 1, further comprising a sensor configured to detect a flatness of the paving material to a screed surface of a screed physically coupled to the dynamic paving material paver.

Clause 15. The dynamic paving material paver of clause 1, further comprising a sensor configured to detect variations in flatness of the sub-base prior to addition of the paving material to the sub-base.

Clause 16. The dynamic paving material paver of clause 1, wherein the material distribution device is a lateral distribution device that includes a conveyor and at least one auger.

Clause 17. The dynamic paving material paver of clause 16, wherein the at least one auger includes at least one rotating auger cover that rotates about the at least one auger.

Clause 18. The dynamic paving material paver of clause 17, wherein the at least one rotating auger cover includes a plurality of rotating auger covers, and the plurality of gates is configured as the plurality of rotating auger covers.

Clause 19. The dynamic paving material paver of clause 1, further comprising a container configured to receive the paving material, and a sensor configured to detect an amount of the paving material within the container.

Clause 20. The dynamic paving material paver of claim 1, further comprising: a tractor portion; a compacting device located proximate to, and behind, the plurality of gates, wherein the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates; and at least one tow-arm that is configured to attach the material leveling device to the tractor portion, wherein the material leveling device includes a screed having a screed surface, and the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base.

Clause 21. A method for dynamically paying a sub-base with a dynamic paving material paver, the method comprising: receiving, via a material distribution device, a flow of a paving material for paving the sub-base; partially obstructing the flow of the paving material from the material distribution device with a plurality of gates located proximate to, and ahead of, the material leveling device in a direction of the flow of the paving material from the material distribution device; and applying the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

Claim 22. The method of clause 21, further comprising compacting, with a compacting device located proximate to, and behind, the plurality of gates, the paving, from the flow of paving material that is not partially obstructed by the plurality of gates, on the sub-base.

Clause 23. The method of clause 22, further comprising controlling a height of the compacting device relative to a screed surface to produce a flat surface of paving material on the sub-base.

Clause 24. The method of clause 23, further comprising compressing the paving material with the compressing device that is disposed between the plurality of gates and the screed surface.

Clause 25. The method of clause 24, wherein compressing the paving material with the compressing device includes compressing the paving material with the plurality of gates.

Clause 26. The method of clause 24, wherein compressing paving material with the compressing device includes compressing the paving material with a plurality of compressors and each of the compressors of the plurality of compressor compresses the paving material to a different height.

Clause 27. The method of clause 24, wherein compressing the paving material with the compressing device includes compressing the paving material with a plurality of compressors and each of the compressors of the plurality of compressor compresses the paving material to a different height.

Clause 28. The method of clause 27, wherein receiving the flow of a paving material includes receiving the paving material from a lateral distribution device that includes a conveyor and at least one auger having plurality of rotating auger covers that rotate about the at least one auger, and partially obstructing the flow of the paving material from the material distribution device with a plurality of gates includes partially obstructing the flow of the paving material with the plurality of rotating auger covers.

Clause 29. A dynamic paving material paver comprising: a material distribution device configured to receive and distribute a flow of a paving material for paving a sub-base; at least one actuator; a plurality of gates located proximate to, and ahead of, the material distribution device in a direction of the flow of the paving material from the material distribution device and configured to distribute the paving material on the sub-base; at least one memory; and at least one processor in signal communication with the material distribution device, the at least one actuator, and at least one memory, wherein the at least one processor is configured to: receive, via the material distribution device, the flow of the paving material; partially obstruct the flow of the paving material from the material distribution device with the plurality of gates utilizing the at least one actuator; and applying the paving material, from the flow of paving material that is not partially obstructed by the plurality of gates, to the sub-base.

Clause 30. A dynamic paving material trench paver comprising: a pair of side walls, where each side wall has a skid at a bottom of the side wall; a rear side wall attached to the pair of side walls at an upper portion of each side wall; a strike-off plate attached to the pair of side walls and the rear side wall at a lower portion of each of the side walls and a lower portion of the rear side wall, wherein a combined height of the strike-off plate and rear side wall is less than a height of each of the side walls and a bottom of the strike-off plate is located above a bottom of the pair of side walls; an at least one actuator; and a plurality of gates attached to the bottom of the strike-off plate and configured to distribute a flow of a paving material on a sub-base, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct the flow of the paving material from the material distribution device, and located proximate to, and ahead of, a material leveling device in a direction of the flow of paving material from the material distribution device.

Clause 31. The dynamic paving material trench paver of clause 30, further comprising a compacting device located proximate to, and behind, the plurality of gates, wherein the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates.

Clause 32. The dynamic paving material trench paver of clause 30 or 31, further comprising a screed having a screed surface, wherein the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base.

Clause 30. The dynamic paving material trench paver of clause 30, 31, or 32, wherein each gate of the plurality of gates is configured to be separately height adjustable, independently adjustable in both height and angle, disposed at a different angle relative to each other gate of the plurality of gates, or any combination thereof.

Clause 31. A dynamic paving material trench paver comprising: a pair of side walls, where each side wall has a skid at a bottom of the side wall; a rear side wall attached to the pair of side walls at an upper portion of each side wall; an at least one actuator; and a plurality of gates attached to the bottom of the rear side wall and configured to distribute a flow of a paving material on a sub-base, wherein the plurality of gates are mechanically coupled to the at least one actuator, configured to partially obstruct the flow of the paving material from a material distribution device, and located proximate to, and ahead of, a material leveling device in a direction of the flow of paving material from the material distribution device.

Clause 32. The dynamic paving material trench paver of clause 31, further comprising a compacting device located proximate to, and behind, the plurality of gates, wherein the compacting device is configured to compact the paving material from the flow of paving material that is not partially obstructed by the plurality of gates.

Clause 33. The dynamic paving material trench paver of clause 32, further comprising a screed having a screed surface, wherein the at least one actuator is configured to control a height of the compacting device relative to the screed surface to produce a flat surface of paving material on the sub-base.

Clause 34. The dynamic paving material trench paver of clause 31, wherein each gate of the plurality of gates is configured to be separately height adjustable, independently adjustable in both height and angle, disposed at a different angle relative to each other gate of the plurality of gates, or any combination thereof.

Other Considerations

Other examples and implementations are within the scope of the disclosure and appended claims. For example, due to the nature of software and computers, functions described above can be implemented using software executed by a processor, hardware, firmware, hardwiring, or a combination of any of these. Features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations.

As used herein, the singular forms “a,” “an,” and “the” include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “includes,” and/or “including,” as used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, unless otherwise stated, a statement that a function or operation is “based on” an item or condition means that the function or operation is based on the stated item or condition and may be based on one or more items and/or conditions in addition to the stated item or condition.

Also, as used herein, “or” as used in a list of items (possibly prefaced by “at least one of” or prefaced by “one or more of”) indicates a disjunctive list such that, for example, a list of “at least one of A, B, or C,” or a list of “one or more of A, B, or C” or a list of “A or B or C” means A, or B, or C, or AB (A and B), or AC (A and C), or BC (B and C), or ABC (i.e., A and B and C), or combinations with more than one feature (e.g., AA, AAB, ABBC, etc.). Thus, a recitation that an item, e.g., a processor, is configured to perform a function regarding at least one of A or B, or a recitation that an item is configured to perform a function A or a function B, means that the item may be configured to perform the function regarding A, or may be configured to perform the function regarding B, or may be configured to perform the function regarding A and B. For example, a phrase of “a processor configured to measure at least one of A or B” or “a processor configured to measure A or measure B” means that the processor may be configured to measure A (and may or may not be configured to measure B), or may be configured to measure B (and may or may not be configured to measure A), or may be configured to measure A and measure B (and may be configured to select which, or both, of A and B to measure). Similarly, a recitation of a means for measuring at least one of A or B includes means for measuring A (which may or may not be able to measure B), or means for measuring B (and may or may not be configured to measure A), or means for measuring A and B (which may be able to select which, or both, of A and B to measure). As another example, a recitation that an item, e.g., a processor, is configured to at least one of perform function X or perform function Y means that the item may be configured to perform the function X, or may be configured to perform the function Y, or may be configured to perform the function X and to perform the function Y. For example, a phrase of “a processor configured to at least one of measure X or measure Y” means that the processor may be configured to measure X (and may or may not be configured to measure Y), or may be configured to measure Y (and may or may not be configured to measure X), or may be configured to measure X and to measure Y (and may be configured to select which, or both, of X and Y to measure).

Substantial variations may be made in accordance with specific requirements. For example, customized hardware might also be used, and/or particular elements might be implemented in hardware, software (including portable software, such as applets, etc.) executed by a processor, or both. Further, connection to other computing devices such as network input/output devices may be employed. Components, functional or otherwise, shown in the figures and/or discussed herein as being connected or communicating with each other are communicatively coupled unless otherwise noted. That is, they may be directly or indirectly connected to enable communication between them.

The systems and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.

Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the configurations. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations provides a description for implementing described techniques. Various changes may be made in the function and arrangement of elements.

Having described several example configurations, various modifications, alternative constructions, and equivalents may be used. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of the invention. Also, a number of operations may be undertaken before, during, or after the above elements are considered. Accordingly, the above description does not bound the scope of the claims.

Number	Date	Country
63454542	Mar 2023	US
63310314	Feb 2022	US
63310572	Feb 2022	US

	Number	Date	Country
Parent	18109848	Feb 2023	US
Child	18616126		US

MULTIPLE GATES FOR DYNAMIC PAVING

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CPC

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Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

Provisional Applications (3)

Continuation in Parts (1)