Patent Application
20150322632
The field of the disclosure relates generally to pavement re-surfacing and, more particularly, to a method and systems for re-surfacing a pavement surface using a material dispersal device (e.g., a surface smoothing box).
Many roadways and other paved surfaces exhibit surface wheel-rutting and general degradation over time. Re-surfacing is a solution which improves skid resistance and the overall quality of these surfaces by applying a uniform layer of a re-surfacing material to the surface. Typically, the layer of re-surfacing material is applied to the surface using a truck, or other mobile device, as it travels along the surface. The re-surfacing material may typically include a slurry material, emulsion oil, and/or an aggregate. The choice of material and method of application may vary depending at least on the project and any desired or necessary characteristics of the re-surfaced pavement.
At least some known systems for pavement re-surfacing use a spray system to apply the re-surfacing material. A spray system is capable of applying a uniform layer of re-surfacing material to the roadway. However, spray systems are susceptible to clogging. For example, a spray system for re-surfacing using a re-surfacing material including aggregate that is sufficiently large may result in clogging of the spray system. In this example, clogging may be lessened by using a re-surfacing material having smaller aggregate. However, this imposes a limit on at least the functionality of the roadway.
In one aspect, a system for re-surfacing a pavement surface is provided. The system includes a material dispersal device that includes a plurality of independent dispersing elements and a plurality of biasing elements. The material dispersal device also includes a plurality of independent dispersing assemblies, wherein each independent dispersing assembly of the plurality of independent dispersing assemblies includes at least one biasing element of the plurality of biasing elements coupled to at least one independent dispersing element of the plurality of independent dispersing elements.
In another aspect, a system for re-surfacing a pavement surface is provided. The system includes a material dispersal device that includes a frame, a first support member adjustably coupled to the frame, a second support member adjustably coupled to the frame, a plurality of independent dispersing elements, and a plurality of biasing elements. The material dispersal device also includes a plurality of independent dispersing assemblies, wherein each independent dispersing assembly includes at least one biasing element of the plurality of biasing elements coupled to at least one independent dispersing element of the plurality of independent dispersing elements. The material dispersal device further includes a primary dispersing device including at least one independent dispersing assembly of the plurality of independent dispersing assemblies coupled to the first support member. The material dispersal device also includes a secondary dispersing device including at least one independent dispersing assembly of the plurality of independent dispersing assemblies coupled to the second support member. The system also includes a delivery mechanism configured to apply a spreadable material to the pavement surface and a dispersing bar configured to disperse the spreadable material on the pavement surface.
In yet another aspect, a method for re-surfacing a pavement surface is provided. The method includes applying a first spreadable material to the pavement surface using a first delivery mechanism. The method also includes dispersing the first spreadable material on the pavement surface using a first dispersing bar configured to apply substantially uniform pressure across the pavement surface.
In the exemplary embodiment, material dispersal device 100 includes a frame 110. An auger 102, a primary dispersing device 104, a secondary dispersing device 106, and a finishing bar 108 are coupled to frame 110. Auger 102 and finishing bar 108 are located at opposite ends of material dispersal device 100. Primary dispersing device 104 is located between auger 102 and finishing bar 108, and secondary dispersing device 106 is located between primary dispersing device 104 and finishing bar 108. In some embodiments, material dispersal device 100 is configured to smooth and/or texture a slurry material that is deposited external to device 100. For example, material dispersal device 100 may be configured without an auger and a finishing bar, and slurry material is applied to the pavement surface using a pump and spray system. A micro-surfacing layer may be fabricated by passing material dispersal device 100 over the applied slurry material.
During operation of material dispersal device 100 in accordance with the example embodiment, slurry material is deposited into material dispersal device 100 at auger 102, smoothed by primary dispersing device 104, further smoothed by secondary dispersing device 106, and texturized by finishing bar 108. More specifically, slurry material is deposited at auger 102 which disperses the slurry material the width of device 100. Primary dispersing device 104 sets the depth, or thickness, of the re-surfacing layer as it passes over the dispersed slurry material. Secondary dispersing device 106 functions similar to primary dispersing device 104 and is used to reduce the amount of slurry material that may be missed by primary dispersing device 104. The texture of the re-surfacing layer is set using finishing bar 108 which may be constructed similarly to either primary dispersing device 104 or secondary dispersing device 106, or may be a single structure (e.g., a squeegee).
Primary dispersing device 104 includes a first support member 112 and a plurality of independent dispersing assemblies 114. First support member 112 is adjustably coupled to frame 110 so that the contact pressure of primary dispersing device 104 on the pavement surface can be changed. Each independent dispersing assembly 114 includes a biasing element 116 coupled to one or more independent dispersing elements 118. Biasing elements 116 of the primary dispersing device 104 are further coupled to first support member 112 and allow each dispersing assembly 114 to move vertically and rotate. Each dispersing assembly 114 is a segmented unit that enhances the ability of device 100 to follow the contour of the pavement surface.
In the exemplary embodiment, each independent dispersing element 118 is either a brush or a blade (e.g., a squeegee). The type of element 118 is determined by the desired application characteristics. For example, a brush may be desirable when applying an emulsion oil to the pavement surface to facilitate urging the emulsion oil into voids, or cracks, in the pavement surface. Alternatively, a blade may be desirable when applying a slurry material to the pavement surface to facilitate application of a smooth and even layer of the slurry material due to its more rigid construction when compared to a brush.
Secondary dispersing device 106 includes a second support member 120 and a plurality of independent dispersing assemblies 114. Second support member 120 is adjustably coupled to frame 110 so that the contact pressure of secondary dispersing device 106 on the pavement surface can be changed. As previously described, each independent dispersing assembly 114 includes a biasing element 116 coupled to one or more independent dispersing elements 118. Biasing element 116 of each independent dispersing assembly 114 of secondary dispersing device 106 is further coupled to second support member 120 and allows each assembly 114 to move vertically and rotate.
In the exemplary embodiment, each independent dispersing assembly 114 of primary dispersing device 104 is offset with respect to each dispersing assembly 114 of secondary dispersing device 106. During operation, some material may not be fully distributed by primary dispersing device 104. For example, some material may pass through voids between the independent dispersing elements and/or voids between the independent dispersing assemblies. Offsetting secondary dispersing device 106 with respect to primary dispersing device 104 facilitates the dispersal of such material.
As described, material dispersal device 100 uniformly applies slurry material to a pavement surface. Independent dispersing assemblies 114 of primary dispersing device 104 and secondary dispersing device 106 are configured to move vertically and rotate so that each independent dispersing assembly 114 is allowed to follow the contour of the pavement surface. Additionally, the support members of primary dispersing device 104 and secondary dispersing device 106 are adjustably coupled to frame 110 of device 100 such that the contact pressure of each can be changed. Therefore, material dispersal device 100 is configurable to apply even contact pressure along the contour of the pavement surface to effect uniform application of slurry material to the pavement surface.
To re-surface a pavement surface, a slurry material 202 is stored in a mobile device (not shown), e.g., in bulk tank storage of the mobile device. Slurry material 202 includes emulsified oil and aggregate. Slurry material 202 may further include one or more of emulsified asphalt, water, catalysts (e.g., Portland cement), chemicals to slow system break, fiber material, and other materials. In one embodiment, slurry material 202 is a micro-surfacing material and a micro-surface is created. In another embodiment, slurry material 202 is a seal coat. In yet another embodiment, slurry material 202 is an emulsion oil and is used to facilitate a crack sealing process. Slurry material 202 may be pre-mixed off site, compounded on the mobile device, or a combination of both.
At least some of slurry material 202 may be mixed 204 with additives 206 to improve ductility, adhesion, crack sealing, toughness, or other similar properties. Mixing 204 may be accomplished using any standard means, e.g., using line injection. The resulting mixture may be distributed on the paved surface using a delivery mechanism 208 (e.g., a spray bar). Delivery mechanism 208 includes one or more apertures or slits, and is configured to controllably apply material to the pavement surface. Delivery mechanism 208 may further be configured to produce a gravity flow or a pressurized flow. In some embodiments, delivery mechanism 208 is a component of the mobile device (or is coupled with the mobile device). In other embodiments, delivery mechanism 208 is a component of material dispersal device 100 (or is coupled with material dispersal device 100). In the example embodiment, delivery mechanism 208 is located between the mobile device and material dispersal device 100, and is a pump and spray system that facilitates application of the slurry material mixture to the pavement surface in a layer with substantially uniform thickness.
When pre-mixed off site and/or compounded on the mobile device, slurry material 202 is blended by the pump action of delivery mechanism 208. Once blended, slurry material 202 will begin to destabilize (or break) and eventually cure. The components of slurry material 202 affect how quickly material 202 will cure after destabilization begins. In one embodiment, delivery mechanism 208 agitates slurry material 202 (e.g., by the pumping action) to slow destabilization while material 202 is transported to the point of application.
In one embodiment, system 200 includes a dispersing bar 210 configured to disperse the slurry material mixture on the pavement surface. Dispersing bar 210 is a brush or blade system similar to primary dispersing device 104 or secondary dispersing device 106. In some embodiments, dispersing bar 210 is a component of the mobile device (or is coupled with the mobile device). In other embodiments, dispersing bar 210 is a component of material dispersal device 100 (or is coupled with material dispersal device 100). In the example embodiment, dispersing bar 210 is located between delivery mechanism 208 and material dispersal device 100. In an alternative embodiment, system 200 includes a thermal bias (not shown) located proximate dispersing bar 210. The thermal bias is used to induce heat to the slurry material mixture, e.g., to reduce the viscosity of the mixture such that it may be more easily urged into voids or cracks in the pavement surface.
In another aspect of system 200, slurry material 202 is mixed 212 then introduced into material dispersal device 100 to re-surface the pavement surface. In the example embodiment, the mobile device includes a pugmill, a pump and spray system, or other device for mixing 212 slurry material 202. The mobile device further includes standard equipment to transport slurry material 202 to material dispersal device 100. Slurry material 202, once mixed 212, is applied to the pavement surface by material dispersal device 100. As previously described, device 100 is configured to uniformly apply slurry material 202 to the pavement surface.
In one embodiment, some or all of slurry material 202 is distributed and dispersed on the pavement surface using a delivery mechanism 214 and a dispersing bar 216. Delivery mechanism 214 is configured to controllably apply slurry material 202 to the pavement surface and dispersing bar 216 is a brush or blade system configured to disperse slurry material 202 on the pavement surface in a layer having substantially uniform thickness.
In another embodiment, slurry material 202 includes a first slurry material, a fiber material, and a second slurry material. During operation, the first slurry material is mixed 204 and applied to the pavement surface, the fiber material is applied to the pavement surface, and the second slurry material is mixed 212 and applied to the pavement surface. In some embodiments, the fiber material is a single fiber material. In other embodiments, the fiber material is a composition including one or more different fiber materials, where each of the different fiber materials has unique size, shape, strength, texture, or other characteristics. For example, a first slurry material is applied to the pavement surface by a first delivery mechanism, a fiber material is applied to the pavement surface by a second delivery mechanism, and a second slurry material is applied to the pavement surface by a third delivery mechanism. In some embodiments, a re-surfaced pavement is created by passing a material dispersal device over the first slurry material, the fiber material, and the second slurry material. In other embodiments, a re-surfaced pavement is created by passing a dispersing bar over the materials, where the dispersing bar is configured to apply substantially uniform pressure across the pavement surface.
In yet another embodiment, slurry material 202 includes a first slurry material and a second slurry material, where the first slurry material and the second slurry material are different. During operation, the first slurry material is mixed 204 and applied to the pavement surface and the second slurry material is mixed 212 and introduced into material dispersal device 100 (or applied to the pavement surface). For example, a first slurry material is applied to the pavement surface by a first delivery mechanism and a second slurry material is applied to the pavement surface by a second delivery mechanism. In some embodiments, the first slurry material is dispersed on the pavement surface by a dispersing bar to facilitate crack filling (or crack sealing) by urging the first slurry material into cracks (or voids) in the pavement surface. In other embodiments, a re-surfaced pavement is created by passing a material dispersal device over the first slurry material and the second slurry material. In yet other embodiments, a re-surfaced pavement is created by passing a dispersing bar over the slurry materials, where the dispersing bar is configured to apply substantially uniform pressure across the pavement surface. In the previous example, the material dispersal device may or may not include an auger.
During operation, a first material is applied 602 to the pavement surface. The first material may be a primer coating, and/or other re-surfacing material such as an emulsion oil, slurry material, or aggregate. The first material is dispersed 604 on the pavement surface. In some embodiments, dispersing 604 the first material on the pavement surface facilitates a crack filling (or crack sealing) process by urging the first material into voids, or cracks, in the pavement surface. In other embodiments, dispersing 604 facilitates uniform spreading of the first material to allow a layering effect with subsequently applied materials.
Slurry material is applied 606 to the pavement surface using a material dispersal device, such as material dispersal device 100 shown in
A second material is applied 608 and dispersed 610 on the pavement surface. The second material may be an emulsion oil, slurry material, or aggregate. In some embodiments, the second material is used to coat or seal the re-surfaced pavement, or to achieve desired coloring of the re-surfaced pavement. Optionally, the re-surfaced pavement is textured 612 to achieve a surface texture of the re-surfaced pavement. For example, texturing may achieve a surface texture that provides an enhanced driving surface when the re-surfaced pavement is a roadway.
During operation, a slurry material is applied 702 to the pavement surface. The slurry material may be applied 702 using an auger, plumbing, or other means. Depending on the application or desired characteristics of the final re-surfaced pavement, the applied material may be a primer coating, a micro-surfacing material, or an emulsion oil.
The applied slurry material is then dispersed 704 on the pavement surface. Dispersing 704 the slurry material on the pavement surface facilitates crack filling (or crack sealing) by urging the material into voids, or cracks, in the pavement surface. Dispersing 704 the slurry material on the pavement surface also facilitates uniform spreading of the material to allow a layering effect with subsequently applied materials. In one embodiment, the slurry material is dispersed 704 using a dispersing bar, such as dispersing bar 210, 216 shown in
In an alternate embodiment, the pavement surface is covered 706 by an aggregate. The aggregate at least partially combines with material applied to the pavement surface. For example, the aggregate may at least partially settle, draw, or be urged into the applied slurry material on the pavement surface. The aggregate used to cover 706 the pavement surface is chosen based on the application or desired characteristics of the final re-surfaced pavement. In some embodiments, the aggregate is a single aggregate. In other embodiments, the aggregate is a composition including one or more different aggregates, where each of the different aggregates has a unique size, shape, texture, or other characteristics.
During operation, a first slurry material is applied 802 to the pavement surface. The first slurry material is applied 802 using an auger, plumbing, or other means. Depending on the application or desired characteristics of the final re-surfaced pavement, the first slurry material may be a primer coating, a micro-surfacing material, or an emulsion oil.
The first slurry material is dispersed 804 on the pavement surface to facilitate crack filling (or crack sealing) by urging the material into voids, or cracks, in the pavement surface. Dispersing 804 the first slurry material on the pavement surface also facilitates uniform spreading of the first slurry material to allow a layering effect with subsequently applied materials. In one embodiment, the first slurry material is dispersed 804 by a brush, a blade, or other suitable device. In other embodiments, the first slurry material is dispersed 804 using a material dispersal device such as device 100 shown in
A second slurry material is applied 806 to the pavement surface using an auger, plumbing, or other means. In one embodiment, the second slurry material includes emulsified oil and aggregate. The second slurry material may also include one or more of emulsified asphalt, water, catalysts (e.g., Portland cement), chemicals to slow system break, fiber material, and other materials. In some embodiments, the second slurry material is an emulsion oil and is used to facilitate a crack sealing process. In some embodiments, the first slurry material and the second slurry material are different materials. In other embodiments, the first slurry material and the second slurry material are the same material. In one embodiment, the second slurry material is applied 806 then dispersed on the pavement surface by a brush, a blade, or other suitable device.
The first slurry material, second slurry material, and pavement surface may be covered 808 by an aggregate. In one embodiment, the aggregate at least partially combines with material applied to the pavement surface. For example, the aggregate may at least partially settle, draw, or be urged into the first slurry material, the second slurry material, or both the first and second slurry materials on the pavement surface. The aggregate used to cover 808 the materials and pavement surface is chosen according to the application or desired characteristics of the final re-surfaced pavement. In some embodiments, the aggregate is a single aggregate. In other embodiments, the aggregate is a composition including one or more different aggregates, where each of the different aggregates has unique size, shape, texture, or other characteristics.
The method and systems described herein facilitate re-surfacing a pavement surface. Specifically, the method and systems for re-surfacing as described above facilitate applying a uniform layer of slurry material to a pavement surface using a material dispersal device configured to follow the contour of the pavement surface. In some embodiments, the re-surfacing material is a micro-surfacing material.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
