SYSTEM AND METHOD FOR ROADWAY PAVEMENT RESTORATION

Abstract

Embodiments of the present invention are generally related to roadway maintenance and repair, and, in particular, to a system and method for restoring asphalt surfaces such as asphalt roadways. In one embodiment, an asphalt restoration system comprising a vehicle with a loading arm, a heater, a heater power generator, a road roller, and an asphalt processor is disclosed. The asphalt restoration system is positioned at a repair site, wherein the heater is offloaded from the vehicle by the vehicle arm and positioned over a repair area. After the repair area is heated, the asphalt processor tills and levels the area, producing a seamless and restored area.

Description

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to roadway maintenance and repair, and, in particular, to a system and method for restoring asphalt surfaces such as asphalt roadways.

BACKGROUND OF THE INVENTION

Conventionally, repairing damaged roadways is done on an ad hoc basis resulting in inefficiencies and varying effectiveness. For example, repair of asphalt surfaces is typically done by removing a damaged section (e.g. a section surrounding a pothole) and re-laying the section with fresh asphalt or simply patching the area with an asphalt compound. Based on the repair capabilities and the experience of the repair crew, ambient grade temperature, asphalt repair material and the effectiveness of the repair equipment, the resulting roadway repair will vary in quality and effectiveness.

Effective and efficient repair of asphalt roadway surfaces requires control of several variables based on the characteristics of the targeted repair site, ambient conditions, capabilities of the repair device and crew and operational requirements. Currently, asphalt repair is performed through application of heat to a targeted area of repair. The resulting softened area (i.e. an area with decreased hardness) is then better able to receive and adhere to replacement or supplement asphalt applied to the area. However, effective softening of the targeted area requires applying heat in a deliberate and controlled fashion adapted to the composition of the asphalt involved, the outside ambient temperature, the temperature of the targeted repair area, and the degree of softening of the targeted area achieved. If the targeted area is improperly heated or softened, the replacement asphalt will not adhere to the repair area and/or seam lines may result. Seam lines are problematic because they reflect a discontinuity between the repair and the asphalt roadway and commonly result in uneven pavement and pothole formation. In current practice, the heat required to soften a targeted asphalt area is a manual iterative process, in which a road crew member measures softness by driving a shovel into the asphalt to evaluate pliability. Such a process widely varies in accuracy based on, for example, the skills of the crew member and the location and frequency of the shovel-measurement.

Furthermore, the current asphalt repair process is energy and time inefficient. The heat source is manually positioned and oriented relative to the targeted repair site, and heat applied to bring the repair area to within a targeted temperature and softness range. Typically, propane fueled heaters are used to heat the repair area as part of a repair process requiring a 4-5 man crew operating over 3-4 hours using heavy equipment. The repaired area is left with a perimeter seam and the repair is guaranteed for 6-9 months.

In contrast, a more efficient asphalt repair process will minimize the time required to bring the material up to a required temperature and softness level while avoiding overheating. If a maximum temperature is exceeded (for example, approximately 375 deg. F), volatile oils burn off and the repair surface may be compromised. However, if the temperature is increased too slowly, more energy is consumed and crew on-site costs will increase.

One recently-developed approach to asphalt repair involves the use of electric-powered infrared heating of a distressed asphalt area followed by use of a multipurpose asphalt processor used to both till and screed the repaired asphalt surface. Such a system and method is described in, for example, U.S. Pat. Nos. 8,556,536, 8,562,247 and D700,633, and U.S. patent application Ser. Nos. 14/049,682 and 13/777,633, as cited above. This system and method requires a 2 man crew, takes about 1 hour, requires less equipment and provides a seamless and permanent repair that may be guaranteed for 18 months. Furthermore, a greater volume of asphalt is recycled than in conventional techniques. Additionally, the use of electrically-powered infrared heating yields a much reduced environmental footprint relative to the use of propane. While effective, such a system may be enhanced to, for example, increase ease of use, reduce total time at a roadway repair site, reduce labor required and minimize roadway lane blockage while providing a seamless, permanent asphalt restoration far superior to conventional asphalt repair methods.

Thus, there is a long-felt need for a system and method that provides a system and method for preserving and/or restoring asphalt surfaces such as asphalt roadways that is easy to use, minimizes labor on site, reduces total time at a roadway repair site and minimizes roadway lane blockage. Further, there is a long-felt need for a system and method that provides a more effective and efficient rejuvenation and preservation of asphalt roadways thereby yielding a more cost and time effective utilization of material, labor, and equipment. Such rejuvenated and preserved roadways will be more robust and less prone to future damage.

SUMMARY OF THE INVENTION

In one embodiment of the invention, an asphalt restoration system and method of asphalt road restoration is disclosed. The method employs an infrared heating unit to heat a repair area and a processor that can both till and screed a repair area. After heating the repair area, rejuvenation materials are applied. The processor then tills the area and screeds it. Lastly, a road roller is used to pinch the joints of the repaired area. All required devices and materials required for the method are transportable by a single vehicle.

The phrases “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

The term “a” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more,” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising,” “including,” and “having” can be used interchangeably.

The term “asphalt”, “asphalt mix” and “asphalt cement” and variations thereof, as used herein, refers to a composite material comprising aggregate and a binder used in construction projects to include road surfaces, parking lots and airports.

The term “aggregate” and variations thereof, as used herein, refers to coarse particulate material used in construction, to include crushed stone, gravel, sand, silt, slag, recycled concrete, geosynthetic aggregates and clay.

The term “binding agent” and variations thereof, as used herein, refers to any material or substance that holds or draws aggregate together to form a cohesive asphalt, to include bitumen and any “bituminous material.”

The term “bulk asphalt” and variations thereof, as used herein, refers to asphalt provided in large quantities, typically by dump truck.

The term “automatic” and variations thereof, as used herein, refers to any process or operation done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material.”

A “communication channel” refers to an analog and/or digital physical transmission medium such as cable (twisted-pair wire, cable, and fiber-optic cable) and/or other wireline transmission medium, and/or a logical and/or virtual connection over a multiplexed medium, such microwave, satellite, radio, infrared, or other wireless transmission medium. A communication channel is used to convey an information signal, for example a digital bit stream, from one or several senders (or transmitters) to one or several receivers. A communication channel has a certain capacity for transmitting information, often measured by its bandwidth in Hz or its data rate in bits per second. Communication channel performance measures that can be employed in determining a quality or grade of service of a selected channel include spectral bandwidth in Hertz, symbol rate in baud, pulses/s or symbols/s, digital bandwidth bit/s measures (e.g., gross bit rate (signaling rate), net bit rate (information rate), channel capacity, and maximum throughput), channel utilization, link spectral efficiency, signal-to-noise ratio measures (e.g., signal-to-interference ratio, Eb/No, and carrier-to-interference ratio in decibel), bit-error rate (BER), packet-error rate (PER), latency in seconds, propagation time, transmission time, and delay jitter.

The terms “communication device,” “smartphone,” and “mobile device,” and variations thereof, as used herein, are used interchangeably and include any type of device capable of communicating with one or more of another device and/or across a communications network, via a communications protocol, and the like. Exemplary communication devices may include but are not limited to smartphones, handheld computers, laptops, netbooks, notebook computers, subnotebooks, tablet computers, scanners, portable gaming devices, phones, pagers, GPS modules, portable music players, and other Internet-enabled and/or network-connected devices.

The term “communication system” or “communication network” and variations thereof, as used herein, refers to a collection of communication components capable of one or more of transmission, relay, interconnect, control, or otherwise manipulate information or data from at least one transmitter to at least one receiver. As such, the communication may include a range of systems supporting point-to-point to broadcasting of the information or data. A communication system may refer to the collection individual communication hardware as well as the interconnects associated with and connecting the individual communication hardware. Communication hardware may refer to dedicated communication hardware or may refer a processor coupled with a communication means (i.e., an antenna) and running software capable of using the communication means to send a signal within the communication system. Interconnect refers some type of wired or wireless communication link that connects various components, such as communication hardware, within a communication system. A communication network may refer to a specific setup of a communication system with the collection of individual communication hardware and interconnects having some definable network topography. A communication network may include wired and/or wireless network having a pre-set to an ad hoc network structure.

The term “computer-readable medium” as used herein refers to any tangible storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a medium may take many forms, including but not limited to, non-volatile media, volatile media, and transmission media. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, or any other magnetic medium, magneto-optical medium, a CD-ROM, any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored.

The term “display” refers to a portion of a screen used to display the output of a computer to a user.

The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

The term “in communication with,” as used herein, refers to any coupling, connection, or interaction using electrical signals to exchange information or data, using any system, hardware, software, protocol, or format, regardless of whether the exchange occurs wirelessly or over a wired connection.

The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.

The term “roadway” as used herein refers to roads of all capacity, whether private or public, of various pavement compositions to include concrete, asphalt, asphalt concrete, and reclaimed asphalt pavement.

The term “repair area” as used herein refers to any atypical or degraded characteristic of a prototypical roadway, to include potholes, ruts, crowns, upheaval, raveling, shoving, stripping, grade depressions, and cracking of various types to include line cracking and alligator cracking.

The term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.

The term “screen,” “touch screen,” or “touchscreen” refers to a physical structure that enables the user to interact with the computer by touching areas on the screen and provides information to a user through a display. The touch screen may sense user contact in a number of different ways, such as by a change in an electrical parameter (e.g., resistance or capacitance), acoustic wave variations, infrared radiation proximity detection, light variation detection, and the like. In a resistive touch screen, for example, normally separated conductive and resistive metallic layers in the screen pass an electrical current. When a user touches the screen, the two layers make contact in the contacted location, whereby a change in electrical field is noted and the coordinates of the contacted location calculated. In a capacitive touch screen, a capacitive layer stores electrical charge, which is discharged to the user upon contact with the touch screen, causing a decrease in the charge of the capacitive layer. The decrease is measured, and the contacted location coordinates determined. In a surface acoustic wave touch screen, an acoustic wave is transmitted through the screen, and the acoustic wave is disturbed by user contact. A receiving transducer detects the user contact instance and determines the contacted location coordinates. The touch screen may or may not include a proximity sensor to sense a nearness of object, such as a user digit, to the screen.

In one embodiment, a method of restoring asphalt in a road surface is disclosed, the method comprising: providing an asphalt restoration system comprising a vehicle with a loading arm, a heater, a heater power generator configured to communicate with the heater, a road roller, and an asphalt processor, wherein the vehicle is configured to simultaneously transport the heater, heater power generator, road roller, and asphalt processor; transporting the asphalt restoration system to a repair site comprising a repair area; offloading the heater from the vehicle using the vehicle loading arm; positioning the heater over the repair area; heating the repair area using the heater to produce a heated repair area; re-positioning the heater away from the heated repair area; applying rejuvenation material to the heated repair area; tilling the heated repair area with the asphalt processor to break up the heated repair area and form a beveled edge on opposing sides of the heated repair area; leveling the heated repair area with a screed of the asphalt processor; compacting the heated repair area with the road roller; loading the heater onto the vehicle using the vehicle loading arm; and loading the road roller and asphalt processor onto the vehicle.

In another embodiment, a method of repairing a void in an asphalt road surface is disclosed, the method comprising: providing an asphalt restoration system comprising a heater, a heater power generator configured to communicate with the heater, and an asphalt processor; transporting the asphalt restoration system to a repair site comprising the void in an asphalt road surface; positioning the heater in proximity to the void; heating asphalt in proximity to the void using the heater to produce a heated repair area; re-positioning the heater away from the heated repair area; tilling the heated repair area with the asphalt processor to break up the heated repair area; leveling the heated repair area with a screed of the asphalt processor; and compacting the heated repair area to create a repaired asphalt road surface with a substantially uniform surface; wherein the asphalt processor is controlled remotely by a remote control device.

In another embodiment, an asphalt restoration system for repairing a void in an asphalt road surface is disclosed, comprising: a heater configured to heat asphalt in proximity to the void to produce a heated repair area; a generator configured to provide power to the heater; an asphalt processor configured to: i) till the heated repair area with a tiller to break up the heated repair area, and ii) level the heated repair area with a screed, the asphalt processor configured to till with the tiller in a first position of use and configured to level with a screed in a second position of use; a remote control device configured to remotely control the asphalt processor; a road roller configured to pinch the heated repair area; a vehicle with a loading arm, the vehicle configured to simultaneously transport the heater, the heater power generator, the asphalt processor, and the road roller; and wherein the loading arm is configured to offload the heater from the vehicle.

This Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention, and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

The above-described benefits, embodiments, and/or characterizations are not necessarily complete or exhaustive, and in particular, as to the patentable subject matter disclosed herein. Other benefits, embodiments, and/or characterizations of the present disclosure are possible utilizing, alone or in combination, as set forth above and/or described in the accompanying figures and/or in the description herein below. However, the Detailed Description of the Invention, the drawing figures, and the exemplary claim set forth herein, taken in conjunction with this Summary of the Invention, define the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above, and the detailed description of the drawings given below, serve to explain the principals of this invention.

FIG. 1 depicts the asphalt restoration system, according to one embodiment of the invention;

FIG. 2 is a flow-chart of one method of use of the asphalt restoration system, using the embodiment of the asphalt restoration system of FIG. 1;

FIG. 3A depicts positioning the asphalt restoration system at a repair site, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3B depicts offloading a heating unit from a vehicle, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3C depicts positioning the heating unit over the repair area, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3D depicts heating the repair area, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3E depicts tilling the repair area by the asphalt processor, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3F depicts leveling the repair area by the asphalt processor, a step of the method of use of the asphalt restoration system of FIG. 2;

FIG. 3G depicts pinching the repair area by the road roller, a step of the method of use of the asphalt restoration system of FIG. 2; and

FIG. 3H depicts loading the equipment onto the vehicle, a step of the method of use of the asphalt restoration system of FIG. 2.

It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

To assist in the understanding of the present invention the following list of components and associated numbering found in the drawings is provided herein:

Reference No. Component
2             Asphalt Restoration System
4             Vehicle
6             Vehicle Loading Arm
8             Heating Unit One
10            Heating Unit Two
12            Electrical Generator
14            Electrical Generator Fuel Container
16            Restoration (Asphalt) Processor
18            Road Roller
20            Asphalt Repair Material
22            Asphalt Repair Tools
24            Worker One
26            Worker Two
28            Power Connection One
30            Power Connection Two
32            Repair Site
34            Repair Area One
36            Repair Area Two

DETAILED DESCRIPTION

FIG. 1 depicts the Asphalt Restoration System 2 at Repair Site 32 comprising Repair Area One 34. Asphalt Restoration System 2 comprises Vehicle 4 with Vehicle Loading Arm 6. Vehicle 4 is configured to transport Heating Unit One 8, Heating Unit Two 10, Electrical Generator 12, Electrical Generator Fuel Container 14, Restoration (Asphalt) Processor 16, Road Roller 18, Asphalt Repair Material 20, Asphalt Repair Tools 22, Worker One 24 and Worker Two 26.

Vehicle 4 may be any commercially-available vehicle capable of transporting the devices and materials described, such as a commercial-grade truck. Vehicle 4 is equipped with a Vehicle Loading Arm 6 that is configured to off-load and on-load one or more heating units, such as Heating Unit One 8 and Heating Unit Two 10, or other components. In one embodiment, the Vehicle 4 includes outriggers to increase stability of the Vehicle 4 during loading operations. In one embodiment, the Vehicle 4 may include towed vehicles, e.g. a flatbed trailer, to transport one or more components, e.g. the Restoration Processor 16. The Vehicle Loading Arm 6 and associated controls (such as hydraulic, electrical) are any of those known to one skilled in the art. In one embodiment, the Vehicle Loading Arm 6 is a lift or a ramp, e.g. a hydraulic lift or a hydraulic ramp.

Each of Heating Unit One 8 and Heating Unit Two 10 comprise heating elements configured to heat asphalt pavement. Each of Heating Unit One 8 and Heating Unit Two 10 are electrically powered infrared heating units, powered by Electrical Generator 12, and are mounted on wheels so as to be readily positioned by a single worker. Such wheels may have wheel-locks to fix the position of the Heating Unit One 8 and Heating Unit Two 10 at a user-selected location, e.g. above Repair Area One 34 and Repair Area Two 36, respectively. In one embodiment, one or both of Heating Unit One 8 and Heating Unit Two 10 are motorized or otherwise configured to move completely or partially without force by a user or worker. A more detailed description of the Heating Unit One 8 and Heating Unit Two 10 is found in the afore-mentioned U.S. Pat. No. 8,556,536 and U.S. patent application Ser. No. 13/777,633.

The Electrical Generator 12 is mounted on Vehicle 4 and is powered by fuel, such as diesel, as stored in Electrical Generator Fuel Container 14. The Electrical Generator 12 is engaged with Heating Unit One 8 and/or Heating Unit Two 10 via Power Connection One 28 and Power Connection Two 30, respectively. Power Connection One 28 and Power Connection Two 30 are any commercially-available electrical connections, to include quick-connect power connectors and a connection which pivots with the direction of the heating units. In one embodiment, the Electrical Generator 12 is a 36 kW generator. In one embodiment, one or both of the Power Connection One 28 and Power Connection Two 30 are engaged with a drum or roller to facilitate the unwinding and/or winding-up of the Power Connection One 28 and/or Power Connection Two 30.

In an alternate embodiment, the Electrical Generator 12 is not mounted on Vehicle 4, e.g. it may be provided as a stand-alone power unit or mounted with the heating unit. In one embodiment, one or more of the Heating Unit One 8 and Heating Unit Two 10 heat asphalt by other than infrared means, e.g. by propane via propane heaters or by convection heating. In one embodiment, one or more of the Heating Unit One 8 and Heating Unit Two 10 heat asphalt by other than propane means, e.g. by infrared heating.

Restoration Processor 16 is a device which functions to both till and screed a repair area, such as Repair Area One 34. More specifically, the Restoration Processor 16 tills a repair area so as to produce a beveled edge at the perimeter of the repair area. Such a beveled edge results in a seamless surface interface between the worked repair area and the unworked repair area. A more detailed description of the Restoration Processor 16 is found in the afore-mentioned U.S. Pat. Nos. 8,556,536; 8,562,247; 8,714871 and D700,633.

Asphalt Repair Material 20 comprises asphalt, aggregate and binding agent in any form, to include as pellets and strips. In one embodiment, the method of the disclosure and/or the device of the disclosure uses an asphalt brick device and method of manufacture as described in the afore-mentioned U.S. patent application Ser. No. 13/931,076.

Asphalt Repair Tools 22 are tools typically used in asphalt repair jobs, comprising rakes and shovels.

In one embodiment, one or more components are automated and/or remotely-operated. For example, Heating Unit One 8 and/or Heating Unit Two 10 may be operated through automatic controls with assistance of a user such as Worker One 24. In one embodiment, the automatic and/or semi-automatic operation of the Heating Unit One 8 and/or Heating Unit Two 10 is that as described in the afore-mentioned U.S. patent application Ser. No. 13/777,633. In one embodiment, one or both of the Road Roller 18 and Restoration Processor 16 are automated and/or remotely-operated, such as by the devices and methods of operation thereof as described in U.S. Pat. No. 8,403,594 to Neumann, U.S. Pat. No. 5,921,708 to Grundl, U.S. Pat. No. 8,267,619 to Munz and U.S. Pat. No. 7,549,821 to Hall, the entire disclosures of each of which are incorporated by reference herein. The control of the remotely-operated afore-mentioned U.S. patent application Ser. No. 13/777,633. In one embodiment, one or both of the Road Roller 18 and/or Restoration Processor 16 are controlled by a communication device and/or a communication system by way of a user display or a user screen. For example, a user may carry or hold a display which presents positional data regarding the Restoration Processor 16 and allows the user, e.g. by way of a joystick, to manipulate the operation of the Restoration Processor 16 (such as moving between a tilling state and a screed state.) In one embodiment, the user controls the Road Roller 18 and/or Restoration Processor 16 through wireless communication means. In one embodiment, the system 2 and/or one or more components e.g. processor 16, comprise a computer-readable medium.

In one embodiment, one or more remote control devices to control one or more of the elements/components of the system 2 may comprise any known means or devices for automatic or semi-automatic control, such as joysticks, buttons, switches and knobs, and any known means or devices to monitor or control status thereof, e.g. displays, gauges, lights and sounds.

In one embodiment, the system and/or components thereof may communicate with a control base station that may be located on-site (e.g. on the vehicle 4) or remotely (e.g. at the dispatch site of vehicle 4, or at the company fleet headquarters.) The control base station may comprise the above monitoring and/or control components. In some embodiments, the control base station may be used to control and monitor multiple asphalt restoration systems 2 operating at different repair sites, reducing the need for personnel at a given site.

FIG. 2 is a flowchart of a general order of one method 100 of use of the asphalt restoration system, using the embodiment of the asphalt restoration system of FIG. 1. The method will be described with reference to FIGS. 1-3. The method starts with Step 102 and ends with Step 124. FIGS. 3A-G provide additional detail regarding most steps of the method 100. The method 100 can include more or fewer steps or can arrange the order of the steps differently than those shown in FIG. 1.

At step 104, an Asphalt Restoration System 2 is provided, as described above. The Asphalt Restoration System 2 is self-contained in a single Vehicle 4, which, among other things, minimizes cost, reduces the footprint of the equipment to include reducing roadway lane blockage, and minimizes the logistical support required as compared with conventional techniques which require multiple vehicles.

At step 106 as depicted in FIG. 3A, the Asphalt Restoration System 2, as transported by Vehicle 4, is positioned at Repair Site 32 comprising Repair Area One 34 and Repair Area Two 36. In one embodiment, the selection and/or identification of a repair site may be in the manner described in the afore-mentioned U.S. patent application Ser. No. 13/742,928. In one embodiment, the repair area, i.e. the distressed area, comprises an asphalt void of no more than three (3) inches in depth. In another embodiment, the distressed area comprises a void of no more than six (6) inches in depth.

At step 108 as depicted in FIG. 3B, the Vehicle Loading Arm 6 is used to off-load one or more heating units at Repair Site 32. In FIG. 3C, Heating Unit One 8 is depicted as engaged with Vehicle Loading Arm 6 as it is off-loaded from Vehicle 4. Heating Unit Two 10 is shown still mounted on Vehicle 4. Repair Site 32 is shown comprising Repair Area One 34 and Repair Area Two 36. In one embodiment, Worker One 24 may manage traffic flow while Worker Two 26 off-loads one or both of heating units. Note that the far right lane of Repair Site 32 remains open to traffic while the two left lanes are closed to effect the repair of repair Site 32.

At step 110 as depicted in FIG. 3C, each of the Heating Unit One 8 and Heating Unit Two 10 are positioned over Repair Area One 34 and Repair Area Two 36, respectively. Further, each of the Heating Unit One 8 and Heating Unit Two 10 are in communication with Electrical Generator 12, as mounted on Vehicle 4, via Power Connection 28 and Power Connection Two 30, respectively. One or both of Power Connection 28 and Power Connection Two 30 may be quick-connect type connectors. Throughout the method 100, two workers are required, that is Worker One 24 and Worker Two 26. In an alternate embodiment, one worker is required. In one embodiment, the Power Connection 28 and/or Power Connection Two 30 additionally or alternately provide other-than-electrical connections, e.g. a hydraulic connection to enable hydraulically-assisted movement and/or positioning of the Heating Unit One 8 and/or Heating Unit Two 10. In one embodiment, the Heating Unit One 8 and/or Heating Unit Two 10 are fitted with sensors, actuators and/or displays to control and/or monitor the heating unit. For example, such sensors may monitor/control the temperature or energy output of a heating unit and may re-position the height of a heating unit above a repair area. In one embodiment, the control and/or monitoring of one or both Heating Unit One 8 and Heating Unit Two 10 is as described in the afore-mentioned U.S. Pat. No. 8,801,325 and U.S. patent application Ser. No. 13/777,633. For example, an automatic controller is used to monitor and manage the heating time, heater orientation, heater temperature, repair area temperature, and/or repair area softness/hardness.

At step 112 as depicted in FIG. 3D, each of the Repair Area One 34 and Repair Area Two 36 are heated by Heating Unit One 8 and Heating Unit Two 10, respectively. In one preferred embodiment, the heating time is between 10 and 30 minutes. In a more preferred embodiment, the heating time is between 10 and 25 minutes. In a most preferred embodiment, the heating time is between 15 and 25 minutes. In one preferred embodiment, the repair area is heated to a temperature between 275 and 425 degrees Fahrenheit. In a more preferred embodiment, the repair area is heated to a temperature between 300 and 400 degrees Fahrenheit. In a most preferred embodiment, the repair area is heated to a temperature between 325 and 375 degrees Fahrenheit. In another preferred embodiment, the repair area is heated to a temperature of at least 325 degrees Fahrenheit. Each of the Heating Unit One 8 and Heating Unit Two 10 are in communication with Electrical Generator 12, as mounted on Vehicle 4, via Power Connection 28 and Power Connection Two 30, respectively. Note that each of Restoration Processor 16, Road Roller 18, Asphalt Repair Material 20 and Asphalt Repair Tools 22 have been offloaded from Vehicle 4 for use at Repair Site 32. At the conclusion of step 112, the repair area is pliable.

At step 114, after removing the Heating Unit One 8 and Heating Unit Two 10 from respective Repair Area One 34 and Repair Area Two 36, these repair areas may be raked (e.g. to remove any asphalt crust) and/or rejuvenation materials applied. During this step, the repair area is rejuvenated. Rejuvenation materials may comprise materials that provide additives and/or rejuvenators that strengthen bonding between the worked (healed) asphalt and the un-worked (surrounding) asphalt, such as rejuvenation strips, and/or polymer bonding pellets. The polymer bonding pellets are sprinkled on the worked area before application of the rejuvenation strips, and function to supplement the strips to further reinforce the seamless fusion between the healed area and the existing asphalt and provide added rigidity to prevent, e.g., rutting. In one embodiment, rejuvenation materials comprise RxEHAB oil strips, polymer bonding pellets and recycled asphalt pavement (RAP). In another embodiment, the devices and methods of the afore-mentioned U.S. patent application Ser. No. 13/931,076 are used at step 114. For example, modular asphalt bricks are applied to the repair area. In one embodiment, the rejuvenation materials are pre-packaged.

At step 116 as depicted in FIG. 3E, the Repair Area One 34 and Repair Area Two 36 are tilled using the Restoration Processor 16, as described in the afore-mentioned U.S. Pat. Nos. 8,556,536; 8,562,247; D700,633 and U.S. patent application Ser. No. 14/049,682. In this step, the rejuvenated repair area is processed in-place wherein a homogenous mix of processed asphalt is created (much like that produced by a batch plant.) Among other things, the Restoration Processor 16 produces a beveled edge at the perimeter of the repaired area, which enables a seamless edge between the worked (healed) and un-worked (surrounding) asphalt. As discussed above, in one embodiment, the tilling operation of the Restoration Processor 16 is automated and/or remotely-operated. In one embodiment, rejuvenation materials are alternatively or additionally applied during and/or after step 116. In one embodiment, at the completion of step 116 the repair area presents an area with a homogenous mix with a consistency similar to new asphalt.

At step 118 as depicted in FIG. 3F, the Restoration Processor 16 is used to screed and level each of Repair Area One 34 and Repair Area Two 36, as described in the afore-mentioned U.S. Pat. Nos. 8,556,536; 8,562,247; D700,633 and U.S. patent application Ser. No. 14/049,682. The existing (unworked) asphalt is used by the Restoration Processor 16 as a grade reference. As discussed above, in one embodiment, the screed and level operation of the Restoration Processor 16 is automated and/or remotely-operated. In one embodiment, rejuvenation materials are alternatively or additionally applied during and/or after step 118.

At step 120 as depicted in FIG. 3G, one or both of Repair Area One 34 and Repair Area Two 36 are compacted (aka pinched) by Worker One 24 using Road Roller 18. That is, the beveled edge between the worked and un-worked asphalt is compressed from the surface downwards, therein “pinching” the beveled edge joint and further realizing a seamless asphalt repair. As discussed above, in one embodiment, the pinch/rolling operation of the Road Roller 18 is automated and/or remotely-operated.

At step 122 as depicted in FIG. 3H, all equipment and personnel that comprise the Asphalt Restoration System 2 are loaded onto Vehicle 4. Such loading includes loading of each of Heating Unit One 8 and Heating Unit Two 10 via Vehicle Loading Arm 6. The method 100 ends at step 124.

In one embodiment, one or more of the components are not carried by a single vehicle 4, e.g. the road roller 18 may be transported separately. In one embodiment, the asphalt repair process does not require the exporting (e.g. hauling away) of excavated asphalt. In one embodiment, the asphalt repair process is non-volatile. In one embodiment, the asphalt repair process is compliant with one or more green industry standards and/or one or more OSHA standards.

In some embodiments, the automatic or semi-automatic control of systems or components, as described above, is implemented by computer hardware, software, or a combination thereof.

Claims

1. A method of restoring asphalt in a road surface, comprising: providing an asphalt restoration system comprising a vehicle with a loading arm, a heater, a heater power generator configured to communicate with the heater, a road roller, and an asphalt processor, wherein the vehicle is configured to simultaneously transport the heater, heater power generator, road roller, and asphalt processor;transporting the asphalt restoration system to a repair site comprising a repair area;offloading the heater from the vehicle using the vehicle loading arm;positioning the heater over the repair area;heating the repair area using the heater to produce a heated repair area;re-positioning the heater away from the heated repair area;applying rejuvenation material to the heated repair area;tilling the heated repair area with the asphalt processor to break up the heated repair area and form a beveled edge on opposing sides of the heated repair area;leveling the heated repair area with a screed of the asphalt processor;compacting the heated repair area with the road roller;loading the heater onto the vehicle using the vehicle loading arm; andloading the road roller and asphalt processor onto the vehicle.

2. The method of claim 1, wherein the heater is an infrared heater.

3. The method of claim 1, wherein the heater comprises wheels to facilitate positioning of the heater.

4. The method of claim 1, further comprising connecting the heater power generator with the heater.

5. The method of claim 4, wherein the heater power generator is an electrical power generator fueled by a hydrocarbon.

6. The method of claim 1, wherein the asphalt processor comprises: a rotatable shaft member having a first end and a second end; anda plurality of tines extending outwardly from the rotatable shaft member comprising a first and second set of outermost tines and a set of inner tines positioned between the first and second set of outmost tines, each of the first and second set of outermost tines comprising a portion that angles inwardly toward the inner set of tines and configured to form the respective first and second beveled edges in the heated repair area.

7. The method of claim 6, wherein the asphalt processor comprises a tiller operable in a first position of use and a screed operable in a second position of use.

8. The method of claim 7, wherein the screed comprises at least two outwardly extending arm structures.

9. The method of claim 1, further comprising a temperature sensor in proximity to the heated repair area, wherein the repair area is heated to a temperature of at least about 325 degree Fahrenheit.

10. The method of claim 9, wherein the heater is in operable communication with a controller, the controller controlling a level of power of the heater power generator based on a temperature measurement from the temperature sensor.

11. The method of claim 1, wherein the heater is operated on at least one of propane and a natural gas.

12. The method of claim 1, further comprising a remote control device configured to remotely control the asphalt processor.

13. A method of repairing a void in an asphalt road surface, comprising: providing an asphalt restoration system comprising a heater, a heater power generator configured to communicate with the heater, and an asphalt processor;transporting the asphalt restoration system to a repair site comprising the void in an asphalt road surface;positioning the heater in proximity to the void;heating asphalt in proximity to the void using the heater to produce a heated repair area;re-positioning the heater away from the heated repair area;tilling the heated repair area with the asphalt processor to break up the heated repair area;leveling the heated repair area with a screed of the asphalt processor; andcompacting the heated repair area to create a repaired asphalt road surface with a substantially uniform surface;wherein the asphalt processor is controlled remotely by a remote control device.

14. The method of claim 13, wherein the asphalt processor comprises a tiller operable in a first position of use and a screed operable in a second position of use, wherein the tiller forms a beveled edge on opposing sides of the heated repair area.

15. The method of claim 14, wherein the screed comprises at least two outwardly extending arm structures.

16. The method of claim 15, wherein the heated repair area is heated to a temperature of at least 325 degree Fahrenheit.

17. The method of claim 16, further comprising applying rejuvenation material to the heated repair area.

18. An asphalt restoration system for repairing a void in an asphalt road surface, comprising: a heater configured to heat asphalt in proximity to the void to produce a heated repair area;a generator configured to provide power to the heater;an asphalt processor configured to: i) till the heated repair area with a tiller to break up the heated repair area, and ii) level the heated repair area with a screed, the asphalt processor configured to till with the tiller in a first position of use and configured to level with a screed in a second position of use;a remote control device configured to remotely control the asphalt processor;a road roller configured to pinch the heated repair area;a vehicle with a loading arm, the vehicle configured to simultaneously transport the heater, the heater power generator, the asphalt processor, and the road roller; andwherein the loading arm is configured to offload the heater from the vehicle.

19. The system of claim 18, wherein the heater is in operable communication with a controller, the controller controlling a level of power of the heater power generator based on a temperature measurement from the temperature sensor.

20. The system of claim 19, wherein the heater is an infrared heater configured to heat the heated repair area to a temperature of at least about 325 degree Fahrenheit.