U.S. patent application number 09/996028 was filed with the patent office on 2003-05-15 for asphalt container systems.
This patent application is currently assigned to Deery American Corporation. Invention is credited to Zentner, Robert K..
Application Number | 20030091389 09/996028 |
Document ID | / |
Family ID | 25542436 |
Filed Date | 2003-05-15 |
United States Patent
Application |
20030091389 |
Kind Code |
A1 |
Zentner, Robert K. |
May 15, 2003 |
Asphalt container systems
Abstract
A road repair kit and/or bridge joint repair kit is comprised of
an outer container, a measured amount of asphaltic material and a
separate and distinct measured amount of aggregate material. In a
preferred embodiment of this invention, the asphaltic material is
in a first consumable container (meltable bag) and the aggregate
material is, likewise, in a second consumable container (meltable
bag) inside the first consumable container.
Inventors: |
Zentner, Robert K.;
(Chicago, IL) |
Correspondence
Address: |
DORR CARSON SLOAN & BIRNEY, PC
3010 EAST 6TH AVENUE
DENVER
CO
80206
|
Assignee: |
Deery American Corporation
|
Family ID: |
25542436 |
Appl. No.: |
09/996028 |
Filed: |
November 15, 2001 |
Current U.S.
Class: |
404/17 |
Current CPC
Class: |
E01C 11/005
20130101 |
Class at
Publication: |
404/17 |
International
Class: |
E01C 007/00 |
Claims
Thus having disclosed my invention, what is claimed is:
1. A road surface repair kit comprising: (1) a premeasured amount
of an asphaltic component that is housed within an outside
container, (2) a premeasured amount of an aggregate component that
is housed within the same outside container, (3) an outside
container that houses both the asphaltic component and the
aggregate component.
2. The road surface repair kit of claim 1 wherein the aggregate
component is at least partially embedded in the asphaltic
component.
3. The road surface repair kit of claim 1 wherein a first inner
container contains a premeasured amount of the asphaltic material
in a separate and distinct second inner container.
4. The road surface repair kit of claim 1 wherein a second inner
container contains a premeasured amount of the aggregate material
in a separate and distinct second inner container.
5. The road surface repair kit of claim 1 wherein the outer
container is made of a meltable material.
6. A bridge joint repair kit comprising: (1) a premeasured amount
of asphaltic component that is housed within an outside container,
(2) a premeasured amount of an aggregate component that is housed
within the same outside container, (3) an outside container that
houses both the asphaltic component and the aggregate
component.
7. The bridge joint repair kit of claim 6 wherein the aggregate
component is at least partially embedded in the asphaltic
component.
8. The bridge joint repair kit of claim 6 wherein a first inner
container contains a premeasured amount of the asphaltic material
in a separate and distinct second inner container.
9. The bridge joint repair kit of claim 6 wherein a second inner
container contains a premeasured amount of the aggregate material
in a separate and distinct second inner container.
10. The bridge joint repair kit of claim 6 wherein the outer
container is made of a meltable material.
11. A road surface repair kit comprising: (1) an outer container
that further comprises a first inner container and a second inner
container; (2) a first inner container for containing a premeasured
amount of an asphaltic material; and (3) a second inner container
for containing a premeasured amount of an aggregate material.
12. The road surface repair kit of claim 11 wherein the first inner
container contains a premeasured amount of the asphaltic material
in a separate and distinct second inner container.
13. The road surface repair kit of claim 11 wherein the second
inner container contains a premeasured amount of the aggregate
material in a separate and distinct second inner container.
14. The road surface repair kit of claim 11 wherein the outer
container is made of a meltable material.
15. A bridge joint repair kit comprising: (1) an outer container
for containing a first inner container and a second container; (2)
a first inner container for containing a premeasured amount of an
asphaltic material; and (3) a second inner container for containing
a premeasured amount of an aggregate material.
16. The bridge joint repair kit of claim 15 wherein the first inner
container contains a premeasured amount of the asphaltic material
in a separate and distinct second inner container.
17. The bridge joint repair kit of claim 15 wherein the second
inner container contains a premeasured amount of the aggregate
material in a separate and distinct second inner container.
18. The bridge joint repair kit of claim 15 wherein the outer
container is made of a meltable material.
19. A road surface repair kit comprising: (1) an outer container
for containing at least two first inner containers and at least two
second inner containers; (2) at least two first inner containers
each containing a premeasured amount of an asphaltic material; and
(3) at least two second inner containers each containing a
premeasured amount of an aggregate material.
20. The road surface repair kit of claim 19 wherein the first inner
container is made of a meltable material.
21. The road surface repair kit of claim 19 wherein the second
inner container is made of a meltable material.
22. The road surface repair kit of claim 19 wherein the outer
container is made of a meltable material.
23. A bridge joint repair kit comprising: (1) an outer container
for containing at least two first inner containers and at least two
second inner containers; (2) at least two first inner containers
each containing a premeasured amount of an asphaltic material; and
(3) at least two second inner containers each containing a
premeasured amount of an aggregate material.
24. The bridge joint repair kit of claim 23 wherein the first inner
container is made of a meltable material.
25. The bridge joint repair kit of claim 23 wherein the second
inner container is made of a meltable material.
26. The bridge joint repair kit of claim 23 wherein the outer
container is made of a meltable material.
27. A road surface repair kit comprising: (1) an outer container
having a first inner container and a second inner container and
wherein the first inner container has a lid that is separate and
distinct from a lid that covers the second container; (2) a first
inner container for containing a premeasured amount of an asphaltic
material; and (3) a second inner container for containing a
premeasured amount of an aggregate material.
28. The road surface repair kit of claim 27 wherein the first inner
container is made of a meltable material.
29. The road surface repair kit of claim 27 wherein the second
inner container is made of a meltable material.
30. The road surface repair kit of claim 27 wherein the outer
container is made of a meltable material.
31. A bridge joint repair kit comprising: (1) an outer container
having a first inner container and a second inner container and
wherein the first inner container has a lid that is separate and
distinct from a lid that covers the second container; (2) a first
inner container for containing a premeasured amount of an asphaltic
material; and (3) a second inner container for containing a
premeasured amount of an aggregate material.
32. The road surface repair kit of claim 31 wherein the first inner
container is made of a meltable material.
33. The road surface repair kit of claim 31 wherein the second
inner container is made of a meltable material.
34. The road surface repair kit of claim 31 wherein the outer
container is made of a meltable material.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to container systems
for road surface and/or bridge joint repair compositions. More
specifically this invention relates to container systems for those
asphaltic (and/or polymeric) materials and aggregate materials used
to make such repairs.
[0003] 2. Description of Related Art
[0004] In the road surface and/or bridge joint repair industry,
those asphaltic components and aggregate components with which
repairs of cracks, potholes and joint systems are made are usually
shipped to a job site in one of two ways. In the first way, a load
(often a pallet-sized load) of individual packages of an asphaltic
material are shipped to a job site. Similarly, a load (again, often
a pallet-sized load) of individual packages of an aggregate
material are shipped to the job site. Ideally, a certain number of
packages of asphaltic material and a certain number of packages of
the aggregate material are removed from their respective pallets,
unwrapped and placed in a melter unit. The certain numbers of
respective packages is intended to create a mixture having a
certain ratio of asphaltic material to aggregate material.
Unfortunately, job-site mistakes are made in getting the right
number of packages of each type of ingredient into the melter. This
results in asphaltic material/aggregate material repair
compositions that have too much or too little of the asphaltic
material relative to the aggregate material.
[0005] The second way that asphaltic components and aggregate
components are shipped to a job site is in the form of packaged
blocks of a composite mixture of the asphaltic component(s) and the
aggregate components. The desired asphalt to aggregate ratio is
therefore maintained. These composite blocks are, however,
relatively expensive to make. This follows from the fact that the
asphaltic component must be melted at the factory (at a
considerable fuel expense) and the aggregate component mixed into
the melted asphaltic material. The resulting asphaltic
material/aggregate material mixture or composite is then placed in
containers where they cool and solidify. The containers are
typically wrapped in an outside cover material such as paper or a
meltable plastic sheet material. Packages have been developed that
eliminate the need to remove or dispose of the container. One type
of such a package is disclosed in, e.g., U.S. Pat. Nos. 5,452,800
and 5,307,608. They teach asphalt packages employing thin
polypropylene films as the sole containment means--and methods for
the manufacture of such.
[0006] U.S. Pat. No. 5,992,628 teaches an asphalt/package system
comprised of an asphaltic composition surrounded by a container
made of a meltable material. That is to say that the container is
melted along with the asphalt when the package is put in a gas
fired melter unit used at a job site. The container is made of a
composition comprised of about 40-90% of an asphalt material and
about 10-60% of a polymer such as propylene, ethylene-propylene,
methacrylates and the like. The container has various physical
features e.g., handles, breakage channels for dividing the
container into fractional submits such as one half, one quarter and
so on.
[0007] U.S. Pat. No. 5,765,686 also teaches packaging asphalt in
consumable packages made of an asphalt/polymer composition. Such
packages are provided with fraction creating (e.g., one half, one
quarter, etc.) breakage line indentations molded into the material
from which the composition is made. A thin, meltable, polymer film
(e.g., polypropylene), is used to provide outside protection for
the package.
[0008] U.S. Pat. No. 2,988,207 ("the '207 patent") teaches a
package system for ready mix concrete. Its sand, or sand and
gravel, components (or other materials) are contained in a paper
outer paper bag. A smaller, moisture sealed, plastic bag, filled
with dry cement, is placed inside the paper bag. The contents of
the outer bag (sand, gravel) as well as the cement contents of the
inner bag (cement) are premeasured to their proper proportions.
They are mixed with water at the job site to produce a concrete
composition.
[0009] U.S. Pat. No. 4,678,363 teaches a road repair truck having
an aggregate hopper and a binder material tank. The aggregate
hopper has a conveyor and a discharge chute for receiving the
aggregate and directing it downwardly. A discharge outlet on the
chute dispenses the aggregate to a pothole, etc. while an asphalt
composition is sprayed on to the aggregate as it is being
dispensed. To this end, the chute is provided with a rotatable
hollow shaft that extends below the outlet of the aggregate
discharge chute. A projection is mounted on the periphery of the
hollow shaft in order to premix the aggregate that is moving
downwardly through the discharge chute. A plate device is attached
to the hollow shaft to make the aggregate swirl and flare outwardly
as it drops downwardly to the road surface. Again, the asphalt
binder is sprayed on the swirling aggregate just as it leaves the
discharge chute (i.e., but before it reaches the roadway).
[0010] U.S. Pat. No. 1,546,185 ("the '185 patent") teaches a road
repair vehicle having partitioned road repair ingredient sections.
A heating box is positioned between the partitions. Heat from a
heater box is circulated through a casing system in order to heat
the as yet unmixed road repair materials.
[0011] U.S. Pat. No. 5,333,969 teaches an automated repair vehicle
in which computer controls direct the mixing of desired amounts of
various road repair composition ingredients.
[0012] U.S. Pat. No. 5,988,935 teaches a road repair vehicle having
a self-contained heating box. The binder used by this vehicle is
not heated separately from the aggregate.
[0013] U.S. Pat. No. 1,512,389 teaches a road repair vehicle having
different compartments such that all of the road repair
compositions are heated separately.
[0014] U.S. Pat. No. 4,511,284 ("the '284 patent") shows a pothole
repair unit in which the asphalt is heated separately from the
separate aggregate. The heated aggregate is then coated with the
heated asphalt.
[0015] These patents fall into two broad categories (1) generalized
packaging methods (for asphalt/polymer materials as well as for
other materials such as concrete ingredients) and (2) asphalt
dispensing vehicles. The asphalt/polymer packaging method patents
(e.g., the '628 patent and the '686 patent) generally teach use of
"consumable" containers. That is to say an asphalt/polymer
container and its asphalt or asphalt/polymer contents are thrown in
a melter as a unit. These containers also are partially divided or
compartmentalized. This is done for the purpose of breaking these
container (and its contents) into smaller sizes (e.g., one half,
one quarter, etc.) at a job site. It should be specifically noted
however that these compartmentalized asphalt packages do not
contain two distinct kinds of ingredients (e.g., a separate and
distinct asphalt ingredient, and a separate and distinct aggregate
ingredient, etc.), but rather a body of a composite material (a
solidified mixture of asphalt/polymer and aggregate).
[0016] The '207 patent teaches a container having two distinct
compartments containing two different materials. This system is
not, however, concerned with asphalt related products. Rather, it
is concerned with packaging a cement/sand (or sand and gravel)
system that will be used to make concrete. The cement absolutely
can not be contacted with moisture before it is mixed with the
aggregate. Hence, it is placed in a tightly sealed, moisture proof,
plastic bag that resides in a second, layered paper, bag that
contains the sand (or sand and gravel) ingredient(s). At the time
of use, the two bags are broken, the materials are mixed with each
other and water is added to the mixture to produce a wet concrete
mixture that is poured into a form and allowed to dry in that
form.
[0017] Thus, none of the above noted patents teach a
compartmentalized package system that has an asphaltic binder
material component (such as an asphaltic/polymer composition) that
is packaged as a separate and distinct material relative to an
aggregate component that also resides in the compartmentalized
package system. Binder/aggregate compartmentalization is found only
in those patents concerned with asphalt laying machines. These
patents generally teach heating the separated ingredients at the
same time, although not necessarily to the same degree. For
example, the vehicle described in the '363 patent has a first
hopper for containing an aggregate material and a second hopper for
containing an additive material. Similarly, the vehicle described
in the '284 patent shows a hopper that holds and dispenses
aggregate, while a separate and distinct tank holds a road
patching, asphaltic material. The '185 patent teaches a system
wherein a heater is placed between a bituminous material tank and
an aggregate hopper. The heater is used to heat these two materials
in a differential manner. The system is particularly concerned with
assuring that the aggregate component is sufficiently heated.
[0018] Thus, the asphalt related group of patents teaches
compartmentalized packages--wherein the compartments hold portions
of the same composite material. The compartments are used as a
means for dividing the composite material at a job site. Another
patent (i.e., the '207 patent) teaches package compartmentalization
of different materials, but the materials are not the same type of
materials used in applicant's road and bridge repair kits. That is
to say that the '207 patent compartmentalizes cement and aggregate
(to make cement repairs) rather than asphalt and aggregate (to make
road and bridge joint repair materials). The '207 patent also
suggests that the cement and sand or sand and gravel will be
thoroughly mixed before water is added. Another group of patents
teaches compartmentalizing asphalt and aggregate in road repair
vehicles. Some of these patents also suggest (e.g., '185 patent)
differential heating levels for the asphalt and aggregate
materials.
[0019] In contrast with the teachings of all of the above patents,
applicant has found that if a body of asphaltic material is
introduced into a melter--as a body--it will more readily melt
relative to a homogeneous mixture or composite of the same
asphaltic material and the same aggregate material. Comparatively
speaking, applicant has found that road and/or bridge repair
processes based upon throwing a separate and distinct body of
asphalt and a distinct body of aggregate into a given melter unit
is a better process than throwing a body of thoroughly mixed or
otherwise composited asphalt and aggregate into that same melter
unit. Assuring that these two distinct materials are in the proper
proportions adds to the propriety of the product created by
subsequently thoroughly mixing these two ingredients once the
asphaltic component is placed in a melted state. Thus, applicant
has developed road repair kits that serve to assure that an asphalt
ingredient is introduced into a melter as a body that is distinct
from an aggregate ingredient body that is also introduced into that
same melter unit. In one particularly preferred embodiment of this
invention, the distinct body of aggregate material is embedded in a
body of asphaltic material. These kits also serve to assure that
the proper proportions of these ingredients will be employed.
SUMMARY OF THE INVENTION
[0020] The present invention has a packaging embodiment and a
method of use embodiment. The packaging embodiment involves the
fact that an overall road or bridge joint repair material/packaging
system is comprised of: (1) an asphaltic component that is housed
within an outside container, (2) an aggregate component that is
housed within the same outside container, (3) an amount of the
asphaltic component and an amount of the aggregate component that
are each premeasured to give a desired ratio of these two
components in a road repair composition or in a bridge joint repair
system, and (4) an outside container that houses both the asphaltic
component and the aggregate component. Again, in one particularly
preferred embodiment of this invention a "distinct" body of
asphaltic material encapsulates a distinct body of aggregate
material (i.e., the two materials are not homogenously mixed).
[0021] The relative proportions of the asphaltic component to the
aggregate component are such that the asphaltic component will
constitute from about 18 weight percent to about 90 weight percent
of the asphaltic component/aggregate component combination.
Conversely, the aggregate component will constitute from about 10
weight percent to about 82 weight percent of the asphaltic
component/aggregate component combination. The weight of the
packaging material itself is not considered in the above
presentation. Generally speaking however, the packing material will
weight from about 1 to about 5 percent of the weight of the
asphaltic component/aggregate component combination.
[0022] In some of the more preferred embodiments of this invention
the asphaltic component will be comprised of an asphaltic material
and an additive material. The asphaltic material will constitute
from about 15 to about 90 weight percent of the asphaltic
component. Conversely the additive material will constitute from
about 10 weight percent to about 85 weight percent of the asphaltic
component. The asphaltic material will be a mixture of bitumens,
especially those obtained as the residue product of petroleum
refining operations. Generally speaking such bitumens are mixtures
of paraffinic and aromatic hydrocarbons and various heterocyclic
compounds containing sulfur, nitrogen and oxygen. The additive
material(s) will generally be synthetic elastomers, polymers,
antioxidants, modifiers and/or reinforcing agents. More
specifically, these additive materials may be made from fibers,
reclaimed tire rubber, polyester, fiber glass, cellulose and/or
carbon black. The aggregate component(s) of the asphaltic
component/aggregate component combination will generally be
comprised particulate materials having average diameters ranging
from about 2 millimeters to about 37.5 millimeters. Particularly
preferred aggregate components for the practice of this invention
will include basalt, granite and/or limestone particles.
[0023] Again, in one of the most particularly preferred embodiments
of this invention, the aggregate component will be at least one
separate and distinct body of aggregate material located
substantially within at least one body of the asphaltic component
in the manner generally depicted in FIG. 1. That is to say that
such an aggregate component is not uniformly or homogeneously mixed
into the asphaltic component, but rather is preferably placed in a
container (bag, box, etc.) which is then at least partially
surrounded by the asphaltic material. The asphaltic material can be
particulate in nature, or it can be a unitary mass formed by at
least partially immersing the aggregate material in a liquid form
(molten) of the asphaltic material and then allowing the asphaltic
material to cool and solidify around the body aggregate material
(and its container). In yet another particularly preferred
embodiment of this invention, the road or bridge joint repair
material/package systems will be comprised of a bag of aggregated
material that is located in an overall container bag (that contains
both the aggregate component and the asphaltic component) which, in
turn, is located in an outside container.
[0024] In other less preferred, but still operative, embodiments of
this invention, the asphaltic component and the aggregate component
are each respectively contained in an overall container bag made of
a meltable polymeric material. That is to say that the asphaltic
component need not be contained in a container bag that also
contains a bag of aggregate material. In the case where the
asphaltic material is in the physical form of pellets or particles
rather than in the form of a block, it is preferred that said
pellets be contained in their own separate and distinct container
and/or in the overall container bag. In still another preferred
embodiment of this invention, a first inner container for the
asphaltic aggregate component and a second inner container for the
aggregate component each will be bag-like containers while the
outer, overall container is a box-like container. In still other
preferred embodiments of this invention, the first and second inner
containers will be made of a consumable plastic material (i.e., a
plastic material capable of being melted under those temperatures
capable of melting asphaltic materials). The first and second inner
containers (e.g., plastic bags) contained in the outer container
(box-like container) are simply thrown into a melter unit while
residing in their respective consumable bags. Thus, the "proper"
amounts of asphalt and aggregate are delivered to the jobsite
melter unit. Hence, job-site measuring mistakes concerning the
relative amounts of the two ingredients are far less likely to
occur. In yet another preferred embodiment of this invention, the
outside container also will be made of a consumable plastic
material as well. In other embodiments, however, the outer
container (e.g., one made of cardboard) is opened, and thereafter
disposed of as trash rather than being placed in a melter unit. In
all such embodiments of the hereindescribed invention, however, the
body of asphaltic material in the overall container has more of an
opportunity to at least partially melt before it is thoroughly
mixed with the aggregate material with which the asphaltic material
is subsequently mixed (e.g., mixed by a stirring action provided by
a jobsite melter unit).
[0025] Again, this invention is based in large part upon
applicant's finding that if a body of asphaltic material is
introduced into a melter, as a distinct body from the aggregate
material, the asphaltic material will more readily melt relative to
a process wherein a mixture (or other composite) of the same
asphaltic material and the same aggregate is introduced in the
melter as a more or less homogeneous mixture. Again, comparatively
speaking, applicant has found that the process of throwing a bag of
asphalt and a bag of aggregate into a given melter is a better
process than throwing a bag of thoroughly mixed asphalt and
aggregate into that same melter. That is to say that applicant has
found that under field conditions an asphaltic component is melted
faster and with less heat consumption (and hence less expense) if
it is not mixed with the aggregate, relative to the time and heat
consumption required to heat a completely blended mixture of
particles of an asphaltic material and particles of an aggregate
material. This is the case whether the mixture is comprised of
distinct particles of asphaltic materials and distinct particles of
aggregate or the mixture is a block of composite material formed by
first melting the asphaltic material and then mixing aggregate
materials into the melted asphaltic material and then letting the
resulting mixture solidify into a composite, monolithic, body.
Based upon these findings, applicant has developed a packaging
system (a "kit") that assures that the asphaltic ingredient is
introduced into the melter as a substantially unified body (i.e.,
not homogenously mixed with an aggregate ingredient) and such that
the desired asphaltic material/aggregate material ratios are
employed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a cut away side view of an embodiment of this
invention wherein a body of aggregate material is embedded in a
body of asphaltic material.
[0027] FIG. 2 is a perspective view of an embodiment of this
invention wherein an inner container of asphaltic material and an
inner container of aggregate material are placed in an outer
container.
[0028] FIG. 3 is a perspective view of an embodiment of this
invention wherein a block of asphaltic material and a container of
aggregate material are placed in an outer container.
[0029] FIG. 4 is a perspective view of an embodiment of this
invention wherein an outside container is comprised of a first
inner container (containing an asphaltic material) and a second
inner container (containing an aggregate material) and a container
dividing device.
[0030] FIG. 5 is a perspective view of an embodiment of this
invention wherein an outside container is comprised of two
containers of asphaltic material and two containers of aggregate
material and further provided with container dividing devices.
[0031] FIG. 6 is a perspective view of an embodiment of this
invention wherein an outside container is comprised of two separate
inner containers that each are provided with a lid.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 depicts a particularly preferred embodiment of this
invention wherein a container/ingredient system 1 for applicant's
road surface repair kit or bridge joint repair kit is placed in a
first or outside container 2 (e.g., a cardboard box, plastic box,
etc.) having one or more lid flaps 3, 4, etc. In this embodiment,
the first or outside container 2 generally serves to contain a
second or inner container 5. This second container 5 is most
preferably in the form of a bag made of a meltable polymeric
material. That is to say that the second container is capable of
being melted under those conditions that will melt an asphaltic
material contained in said second container. This second container
holds a body of asphaltic material 6 that can be in a block form
such as that depicted in FIG. 1 or in the form of a bag of granular
material. Regardless of its physical form, the body of asphaltic
material 6 will preferably at least partially encapsulates a third
container 7. This third container 7 contains a measured portion of
an aggregate material 8. The third container also is most
preferably in the form of a bag made of a meltable polymeric
material. If the outside container 2 is itself made of a meltable
polymeric material, the entire outside container 2 and its contents
can be thrown into a jobsite melter unit when road or bridge
repairs are to be made. If the outside container is made of
cardboard or some other nonmeltable material, the second or inner
container 5 is removed from the outside container 2 and placed in
the melter unit and the outside container disposed of as trash.
[0033] FIG. 2 depicts an embodiment of this invention wherein a
container system 10 for applicant's road surface repair and/or
bridge joint repair kit. The system 10 is comprised of an outer
container 12, a first inner container 14 for holding a measured
amount of asphaltic material and a second inner container 16 for
holding a measured amount of an aggregate material. The top 18 of
the container 12 is preferably provided with a lid (not shown) and
handles 20 for lifting the outer container 12 by hand. The first
container 14 can likewise be provided with one or more handle(s)
22. Similarly, the second container 16 can be provided with one or
more handle(s) 24. In a particularly preferred embodiment of this
invention, the first inner container 14 (and its handles 22, if
any), the second inner container 16 (and its handles 24, if any)
and/or the outer container 12 all will be made of meltable
polymeric materials. Preferably such materials will preferably melt
at road repair melter unit operating temperatures (e.g., above
about 150.degree. F. and up to about 400.degree. F.).
[0034] Since, these containers 12, 14 and 16 are likely to be
lifted and otherwise handled by workers at a jobsite, their weight
should be suitable for such lifting and handling by such workers.
For example, applicant prefers the outside container 12 and its
contents (e.g., first container 14 and its asphaltic contents and
second container 16 and its aggregate contents) be less than about
60 pounds. Systems weighing between about 30 and 50 pounds are even
more preferred. Generally speaking the asphaltic component of
applicant's overall system will represent from about 18 weight
percent to about 90 weight percent of the overall system 10. The
aggregate component of the overall system will generally range from
about 82 to about 10 weight percent of a system.
[0035] FIG. 3 depicts an alternative embodiment of this invention
wherein an asphaltic component of the system 10' is a single block
of asphaltic material 14'. Such a block 14' may be provided with
handles 22' to facilitate manual lifting thereof. Such a block 14'
may be (but need not) be covered by a layer of sheet-like packaging
material. Here again, in some of the more preferred embodiments of
this invention, such a layer of sheet-like packaging will be
meltable under the melter unit heat conditions used to create the
final form of the road surface, or bridge connector, repair
composition. The outer container 12(W) shown in FIG. 3 is shown
provided with another handle system 20' that is preferably made of
a meltable polymeric material. However, in those cases where the
outer container 12(W) is made of a non-meltable material (e.g.,
cardboard) that is to be disposed of as trash (rather than melted
in the melter unit) the handles can be made of non-meltable
materials.
[0036] FIG. 4 depicts a container system wherein an outside
container 12(X) is comprised of two components 12(A) and 12(B)
comprise a single unit for purposes of shipping and handling. That
is to say the two components 12(A) and 12(B) are joined together as
a unit. The first component 12(A) can, for example, contain an
asphaltic component (not otherwise shown) while the second
component 12(B) contains an aggregate component (otherwise not
shown). The two components 12(A) and 12(B) are shown joined at an
interface plane 12(5), 12(6), 12(7) and 12(8). That is to say that
the right side of the 12(A) component abuts against (and is joined
with) the left side of the 12(B) component. The container 12 is
preferably provided with a separation device such lines of
perforation 12(5) to 12(6), 12(6) to 12(7), 12(7) to 12(B) and
12(8) to 12(5). In another embodiment of this packaging system, the
interface between the right side of the 12(A) component and the
left side of the 12(B) component are affixed to each other by a
layer of glue which is such that the two components 12(A) and 12(B)
can be separated from each other at a job site, so that an
asphaltic component contained in component 12(A), can be placed in
a melter unit independent of an aggregate material contained in
component 12(B). In some of the more preferred embodiments of this
invention, both a container for components 12(A) and 12(B) will be
made of a meltable material.
[0037] FIG. 5 depicts a container system wherein an outside
container 12(Y) is comprised of two first components 12(A)' and
12(B)' and two second components 12(C') and 12(D'). Together all
four of these components comprise a single unit for purposes of
shipping and handling. The first two components 12(A)' and 12(B)'
can, for example, contain an asphaltic component (not otherwise
shown) while the second two components 12(C)' and 12(D)' contain an
aggregate component (otherwise not shown). In FIG. 5 components
12(A)' and 12(B)' are shown joined at an interface plane 12(5),
12(6), 12(7) and 12(8). That is to say that the right side of the
12(A)' component abuts against (and is joined with) the left side
of the 12(B)' component. Similarly components 12(B)' and 12(C)' are
joined at interface 12(9), 12(10), 12(11) and 12(12) while
components 12(C)' and 12(D)' are joined at interface 12(13),
12(14), 12(15) and 12(16). The outside container is preferably
provided with a separation device at each of these interfaces so
that the asphaltic components those e.g., contained in container
component 12(A)' and 12(B)', can be placed in a melter unit
independent of the aggregate material contained in components
12(C)' and 12(D)'.
[0038] FIG. 6 depicts an embodiment of this invention wherein an
outside container 12(Z) is comprised of two separate inner
containers 12(A)" and 12(B)". In effect the outside container 12(Z)
defines two separate and distinct void spaces 26 and 28 that are
each provided with respective lids 30 and 32. In the embodiment
shown in FIG. 6, a block of asphaltic material 14" (having a handle
indentation 22") is shown being removed from void space 26. Thus,
this block of asphaltic material 14" can be separately removed from
the outside container 12(Z) and placed in a melter unit.
Thereafter, the aggregate contents of the second void space 12(B)"
can be put into the melter. If the outer container 12(Z) were made
of a meltable material, the entire container and its contents
(contained in void spaces 26 and 28) could be placed in a melter
unit. If the outer container 12(Z) is made of a non-meltable
material, the lid 32 for the 12(B)" side of the container 12(Z)
could be opened and its aggregate contents emptied into a melter.
In this case these aggregate ingredients could be in a loose form
in the 12(B)" inner container or they could be in another container
such as a meltable bag or box.
[0039] A particularly preferred packaging or kit system of this
patent disclosure comprises (1) an outer container made from a
meltable and hence "consumable" composition comprising an asphaltic
material and at least one polymer, and wherein said outer container
has a structure comprising a first box-like component that contains
an asphaltic material, a second box-like container that contains an
aggregate material and a container breakage device such as
indentations, notches, perforations or break channels extending
around a parameter of the outer container so that the breakage
device can serve to divide the outer container into two or more
portions. Such a consumable asphalt-polymer composition is
preferably made by injection-molding. The outer container end walls
may also include horizontal handhold portions.
[0040] Preferably, any meltable outer containers used in the
practice of this invention will be comprised of asphalt/polymer
compositions comprising, by weight, from about 50% to about 80% of
an asphalt material and from about 20% to about 50% of a polymer
material. In general, the polymer material used in such
asphalt/polymer compositions can be any polymer or mixture of
polymers that is compatible with the asphalt component thereof and
enables the outer container to have the desired physical properties
(e.g., mechanical strength and meltability). Exemplary polymers
that may be used as a component of the polymer material used as a
component of such asphalt/polymer compositions will include (but
not be limited to) polymers selected from the group consisting of
propylene, ethylene-propylene copolymers, and butylene copolymers.
Copolymers of acrylates and methacrylates, such as butyl, propyl,
ethyl, or methyl acrylate or methacrylate copolymerized with
ethylene, propylene, or butylenes, can be used as well. One or more
filler, modifier and/or reinforcing materials such as crushed
stone, glass and other synthetic fibers, talc, calcium carbonate,
silica or reclaimed materials also can be added to such
asphalt/polymer compositions in concentrations of 0 to 15 weight
percent of the overall asphalt/polymer/filler/modifier system.
[0041] A consumable (i.e., meltable) outer container for
applicant's road or bridge joint repair systems preferably have
walls with a thickness of about 0.25 inches, and may be formed by a
process such as rotoforming, thermoforming, or injection molding. A
given polymer material and/or another ingredient may advantageously
enhance the properties of the asphaltic material for paving
purposes, such as high-temperature performance as measured by,
e.g., the Federal Highway Association's pending Strategic Highway
Research Program (SHRP) specification, when the materials
comprising the system is melted. Exemplary polymers for improving
asphalt paving properties are ethylene vinyl acetate,
ethylene-malic anhydride copolymers and polypropylene. The
composition of the outer containers also may optionally include one
or more fillers, such as organic or inorganic fibers.
EXAMPLE I
[0042] A road repair composition for the practice of this invention
would be comprised of (1) from about 18 to about 90 weight percent
(wt. %) asphaltic material, (2) from about 2 to 24 wt. % synthetic
elastomers and/or polymers and (3) from about 5 to 50 weight
synthetic and naturally occurring modifier materials such as clays
(e.g., kalinite), diatomaceous earth, calcium carbonate and fiber
may be part of the system. Relatively small amounts (e.g., 5-10 wt.
%) antioxidants such as carbon black-sulfur also may be employed. A
preferred specification relating to the physical properties of the
binder portion of such a composition (and the ASTM test method used
to test that property) are given in Table I.
1 TABLE I Property Test Method Typical Specification Cone Pen @ 25
C. ASTM D-5329 90 Maximum Resilience @25 C. ASTM D-5329 25% Minimum
Softening Point ASTM D-36 175 Deg. F. Minimum Flow @ 60 C ASTM
D-5329 3 MM Maximum Curing Time Moving Traffic 30 Minutes
Maximum
EXAMPLE II
[0043] Another typical asphaltic material for a road repair
composition would be comprised of about (1) 30 to about 70 weight
percent (wt. %) asphaltic material, (2) from about 2 to about 18
wt. % synthetic elastomers or polymers and (3) from about 6 to
about 40 wt. % percent modifiers and antioxidants. The physical
properties and specifications relating to the binder portion of
this composition (and the ASTM test for that property) are given in
the following Table II.
2 TABLE II Property Test Method Typical Specification Cone Pen @ 50
C. ASTM D-5329 90 Maximum Flow @ 70 C. ASTM D-5329 5 MM Maximum
Softening Point ASTM D-5329 180 Deg. F. Minimum
[0044] A preferred bridge joint repair composition would be
comprised of: (1) 40-70 weight percent asphaltic material, (2) 3-20
weight percent polymers or elastomers and (3) 10-20 weight percent
synthetic or natural occurring modifiers. The remainder of the
system would be an aggregate material that comprised from about 15
to about 75 percent of the overall aggregate/asphaltic material
system. A typical specification relating to the physical properties
of the binder portion (and ASTM test methods) of such a bridge
joint repair composition are given in the following Table III:
3 TABLE III Property Test Method Typical Specification Penetration
@ 25 C. ASTM D-5329 90 Maximum Flow @ 60 C. ASTM D-5329 3 MM
Maximum Softening Point ASTM D-36 180 Deg. F. Minimum Resilience
ASTM D-5329 30 Minimum
[0045] Although the preceding disclosure sets forth a number of
embodiments of the present invention, those skilled in this art
will well appreciate that other arrangements or embodiments, not
precisely set forth in the specifications of this patent
disclosure, could be practiced under the teachings of the present
invention. Therefore, the scope of this invention should only be
limited by the scope of the following claims.
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