U.S. patent application number 15/725915 was filed with the patent office on 2018-02-01 for colored composite pavement structure.
The applicant listed for this patent is BASF SE, Pervious Paving Contractors LLC. Invention is credited to David K. Bower, William Handlos, Steven Hicks.
Application Number | 20180030238 15/725915 |
Document ID | / |
Family ID | 44624980 |
Filed Date | 2018-02-01 |
United States Patent
Application |
20180030238 |
Kind Code |
A1 |
Hicks; Steven ; et
al. |
February 1, 2018 |
COLORED COMPOSITE PAVEMENT STRUCTURE
Abstract
A process for making a colored composite pavement structure
comprising silylated glass aggregate particles and a polymeric
binder composition is disclosed. Systems and methods are also
disclosed for providing a colored composite material that cures
into a pavement structure. In one embodiment, a colorant
concentrate is provided by combining an inorganic colorant with a
portion of a first component of a polymeric binder composition. The
colorant concentrate can then be combined with the first and second
components of the polymeric binder composition to provide a colored
polymeric binder composition. The colored polymeric binder
composition may then be applied to silylated glass aggregate
particles to provide a colored composite material that cures into a
pavement structure.
Inventors: |
Hicks; Steven; (Brownstown,
MI) ; Bower; David K.; (Canton, MI) ; Handlos;
William; (Manitowoc, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BASF SE
Pervious Paving Contractors LLC |
Ludwigshafen am Rhein
Higbee |
MO |
DE
US |
|
|
Family ID: |
44624980 |
Appl. No.: |
15/725915 |
Filed: |
October 5, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13977464 |
Sep 13, 2013 |
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PCT/US2010/062433 |
Dec 29, 2010 |
|
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15725915 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 14/22 20130101;
C08K 3/40 20130101; Y10T 428/24372 20150115; C04B 14/22 20130101;
E01C 19/104 20130101; E01C 7/085 20130101; C04B 26/16 20130101;
C04B 26/16 20130101; E01C 7/35 20130101; C04B 40/0028 20130101;
C04B 2111/0075 20130101; C04B 20/1051 20130101; C04B 14/22
20130101; C03C 1/024 20130101; C04B 2103/54 20130101; C04B 40/0028
20130101; C08K 9/06 20130101; C03C 1/002 20130101 |
International
Class: |
C08K 3/40 20060101
C08K003/40; E01C 19/10 20060101 E01C019/10; E01C 7/35 20060101
E01C007/35; E01C 7/08 20060101 E01C007/08; C04B 26/16 20060101
C04B026/16; C03C 1/00 20060101 C03C001/00; C03C 1/02 20060101
C03C001/02; C04B 14/22 20060101 C04B014/22; C08K 9/06 20060101
C08K009/06 |
Claims
1-9. (canceled)
10. A mixing system for producing a colored composite material
comprising at least one aggregate, a two component polymeric binder
composition comprising a first component and a second component
reactive with the first component, and a colorant concentrate, the
mixing system comprising: an aggregate vessel for holding the
aggregate; a first vessel for holding the colorant concentrate; a
second vessel for holding the first component of the polymeric
binder composition; a third vessel for holding the second component
of the polymeric binder composition; a mixer in fluid communication
with the first, second and third vessels for mixing the first
component, the second component, and the colorant concentrate
together to form a colored polymeric binder composition; an
applicator constructed and arranged to apply the colored polymeric
binder composition onto the aggregate at an application rate; and a
mixing apparatus in communication with the aggregate vessel and the
spray assembly, the second mixing apparatus being arranged to mix
the glass aggregate particles with the colored polymeric binder
composition to provide a colored composite material at a production
rate.
11. The mixing system of claim 10, wherein the mixer is a static
mixer or an impingement mixer.
12. The mixing system of claim 10, further comprising a conveying
system arranged to transport the aggregate from the aggregate
vessel to the mixing apparatus at a transport rate.
13. The mixing system of claim 10, wherein the mixing apparatus
comprises an auger rotatably disposed within a housing.
14. The mixing system of claim 10, further comprising a first pump
in fluid communication with the first vessel and the mixer; a
second pump in fluid communication with the second vessel and the
mixer; and a third pump in fluid communication with the third
vessel and the mixer.
15. The mixing system of claim 14, further comprising a controller
for controlling the operation of the first pump, the second pump,
the third pump, and the first mixing apparatus, the controller
being for controlling the application rate of the colored polymeric
binder composition and the production rate of the colored composite
material.
16. The mixing system of claim 15, wherein the first pump is
arranged to deliver the colorant concentrate from the first vessel
to the second vessel.
Description
[0001] This application is being filed on 29 Dec. 2010, as a PCT
International Patent application in the name of Reynolds Consumer
Products, Inc., a U.S. national corporation, and BASF Corporation,
a U.S. national corporation, applicants for the designation of all
countries except the U.S., and Steven Hicks, a citizen of the
United States, and David K. Bower, a citizen of the United States,
and William Handlos, a citizen of the United States, applicants for
the designation of the U.S. only.
TECHNICAL FIELD
[0002] This disclosure relates to composite pavement structures,
and systems and methods for making composite pavement structures
comprising silylated glass aggregate and colored polymeric binder
compositions.
BACKGROUND
[0003] Waste or recycled glass is commonly provided for secondary
uses through widespread recycling programs. One such secondary use
of this type of glass is as a constituent component in pavement
structures, for example parking surfaces. However, the potential
applications for pavement structures comprising recycled glass can
be limited where specific structural standards must be met and
where a specific color or aesthetic affect of pavement is
specified. Improvements in aggregate pavement structures are
desired.
SUMMARY
[0004] A process for making a colored composite pavement structure
is disclosed. The process may include the steps of providing a
colorant, such as an inorganic pigment powder, having a first color
and providing a first component and a second component of a
polymeric binder composition. The colorant can be combined with a
dilutant, such as a portion of the polymeric binder composition
first component, to provide a colorant concentrate having about 10
to about 35 parts by weight colorant based on 100 parts by weight
colorant concentrate. The colorant concentrate can then be combined
with the first and second components of the polymeric binder
composition to provide a colored polymeric binder composition
having about 0.1 to about 10 parts by weight colorant powder based
on 100 parts by weight of colored polymeric binder composition.
Silylated glass aggregate particles may also be provided ranging
from about 1/16 inch to about 1/2 inch in diameter wherein the
glass aggregate particles are mixed with the colored polymeric
binder composition. Subsequently, the polymeric binder composition
can be allowed to react and bond with the glass aggregate particles
to provide a colored composite material which subsequently cures to
form a colored composite pavement structure.
[0005] A mixing system for producing a colored composite material
that can cure into a colored composite pavement structure is also
disclosed. The mixing system is for mixing at least one aggregate,
a two component polymeric binder composition comprising a first
component and a second component reactive with the first component,
and a colorant concentrate. The mixing system can include an
aggregate vessel for holding the aggregate, a first vessel for
holding the colorant concentrate, a second vessel for holding the
first component of the polymeric binder composition, and a third
vessel for holding the second component of the polymeric binder
composition. The mixing system may also include a mixer in fluid
communication with the first, second and third vessels for mixing
the first component, the second component, and the colorant
concentrate together to form a colored polymeric binder
composition. An applicator, such as a spray assembly, may also be
provided that is constructed and arranged to apply the colored
polymeric binder composition onto the aggregate at an application
rate. Additionally, a mixing apparatus in communication with the
aggregate vessel and the applicator may also be provided to mix the
glass aggregate particles with the colored polymeric binder
composition to provide a colored composite material curable into a
pavement structure at a production rate. It is also possible to
utilize a conveying system to transport the aggregate from the
aggregate vessel to the mixing apparatus, and to provide pumps from
each of the first, second and third vessels to pump fluid from the
vessels and either to one of the other vessels or to the mixer. A
controller may also be provided to control the application rate of
the colored polymeric binder composition onto the glass aggregate
and the production rate of the colored composite material curable
into a colored composite pavement structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic showing a method for providing a
colored composite pavement structure.
[0007] FIG. 2 is a schematic showing a first embodiment of a system
for providing a colored composite pavement structure.
[0008] FIG. 3 is a schematic showing a second embodiment of a
system for providing a colored composite pavement structure.
[0009] FIG. 4 is a schematic showing a cross-section of a colored
composite pavement structure having a top coating.
[0010] FIG. 5 is a schematic showing a system for providing a
colored composite pavement structure on a mobile platform.
DETAILED DESCRIPTION
[0011] This disclosure relates to a process for making a colored
composite pavement structure comprising glass aggregate particles,
a polymeric binder composition, and a colorant. One example of such
a process is shown in FIG. 1.
[0012] In one step of the process, glass is provided and
subsequently modified into glass aggregate particles. Although this
disclosure discusses using glass as the aggregate in the composite
pavement structure, one skilled in the art will appreciate that
other aggregates, such as rock, may be used in combination or
instead of glass aggregate. Where glass is used, the glass may be
of any type and may be clear, tinted, and/or colored. Preferably,
the glass is post-consumer waste recycled glass such that overall
costs and environmental costs are minimized. The waste glass can be
modified in a variety of ways, such as in the manner described in
U.S. Patent Application Publications 2009/0067924 and 2009/0067925
to Kaul, both of which are hereby incorporated by reference. The
glass aggregate particles are formed from glass that has been
crushed, tumbled and heated to round its edges and remove non-glass
impurities. A suitable recycled glass is described in U.S. Pat. No.
7,041,221 to Arnott, which is hereby incorporated by reference.
Waste glass is prepared by crushing the glass to desired
dimensions, e.g., 1/16 inch to about 1 inch, preferably about 1/4
inch to about 1/2 inch, more preferably about 3/8 inch. It is
believed that reducing the average diameter of the glass reduces
spalling of the aggregate from the composite pavement structure,
once installed. The glass may be crushed using an impact crusher,
hammer mill, cone crusher or a roller crusher. Preferably, the
recyclable glass is crushed using roller crusher as better oil
adsorption can be achieved.
[0013] Any order of pre-crushing, pre-screening, crushing, cleaning
and drying may be used. In a preferred embodiment however, the
crushed glass is first pre-crushed and pre-screened. If the glass
is clean, no pre-crushing or pre-screening is required. The
pre-crushed glass is pre screened through a mesh, which may include
an inch mesh, a combination of double or triple deck screens or at
least two meshes. Once pre-screened through the mesh, preferably
the glass is further crushed using a roller crusher and
subsequently, the crushed glass is dried, after cleaning,
preferably at a temperature of at least 100.degree. F. or, more
preferably, at a temperature of at least 350.degree. F.
Subsequently, the crushed glass is screened, preferably through at
least a 40 mesh screen, or more preferably through a 30 mesh
screen, or most preferably through a 20 mesh screen. It is noted
that the above described crushing process can result in about 50
percent by weight glass aggregate particles and about 50 percent by
weight glass sand particles. Suitable grades of glass are
commercially available from Glass Plus Inc. of Tomahawk, Wis.
[0014] Once the waste or recycled glass has been modified to form
glass aggregate particles, the particles can be exposed to a
coupling agent wherein the coupling agent reacts with and bonds to
the glass to form primed glass aggregate particles. As used in this
application, the phrase "primed glass aggregate particles" is meant
to describe glass aggregate particles whose exterior surfaces have
been at least partially coated by a substance that has chemically
reacted with and bonded to the exterior surfaces. As used in this
application, the phrase "coupling agent" is meant to include any
substance that chemically reacts and bonds with glass and a
polymeric binder composition to form a stronger bond between the
glass and polymeric binder composition, as compared to a direct
bond between glass and the polymeric binder composition. Exemplary
coupling agents include silanes with functional groups of hydroxyl,
thiol, epoxy, and/or primary and secondary amines. A particularly
useful example of a coupling agent is aminosilane which will cause
glass aggregate particles to become primed, or more specifically,
silylated or silanized. It is noted that any silane or silanol
functional group will operate to prime or silylate the glass
aggregate particles. However, aminosilane is preferred because
aminosilane is readily soluble in water meaning that an organic
solvent is not required. As such, the use of aminosilane in an
aqueous solution lowers the overall expense of the described
process. Aminosilane concentrate is available commercially from
Momentive Performance Materials of Albany, N.Y., examples of which
are sold as SILQUEST.RTM. A-1100 and SILQUEST.RTM. A-1120. The
priming or silylation process may be performed in a variety of
ways, such as in the manner described in Patent Cooperation Treaty
Application PCT/US10/58582 filed on Dec. 1, 2010, the entirety of
which is hereby incorporated by reference. Once treated, the glass
aggregate particles may be stored in a variety of discrete
containers, such as superstacks and drums. Alternatively, the
particles may be held in larger bulk quantities, as is the case
with railcars and tankers.
[0015] Once the silylated glass aggregate particles have been
transported to an end use site, the aggregate may be mixed with a
polymeric binder composition to form a composite pavement
structure. The polymeric binder composition may also be colored to
form a colored composite pavement structure, as discussed in detail
later. A full discussion of polymeric resin binders, and their use
in mixing with aggregates to form a composite pavement structure,
is provided in Patent Cooperation Treaty Application
PCT/EP2010/058989, filed on Jun. 24, 2010, the entirety of which is
incorporated by reference herein. A further discussion of such
binders and their use is provided in U.S. Patent Application
Publications 2009/0067924 and 2009/0067295 to Kaul. Other suitable
binder compositions, for purposes of the present invention, are
disclosed as "elastomeric compositions" in U.S. Provisional patent
Application Ser. No. 61/288,637, the disclosure of which is
incorporated in its entirety by reference herein.
[0016] One example of a polymeric binder composition is the
reaction product of a two-part composition comprising a first
component and a second component. As such, it is to be appreciated
that the term two-component refers to these components. Other
additional components may be used. The binder composition may be
referred to in the art as a 2K system. The first and second
components are mixed to form the reaction product of the binder
composition. The term reaction product as used herein is intended
to encompass all stages of interaction and/or reaction between the
first and second components, including reaction products of the
first and second components, even when the reaction product
contacts the aggregate to form the composite material. Generally,
the reaction product begins to form when the first and second
components come into contact with each other. In one embodiment,
the reaction product is a polyurethane wherein the first component
is an isocyanate component and the second component is an
isocyanate-reactive component. Table I below shows the constituents
and properties of a polymeric binder composition suitable for use
with the disclosed systems and processes:
TABLE-US-00001 TABLE I Polymeric Binder Composition Components and
Properties Resin Component (components by weight %) Hydrophobic
Polyol (castor oil, commercially available 92.45 from Eagle
Specialty Products, Inc. Chain Extender (DPG) 7.00 Molecular Sieve
(3A) 0.50 Antifoaming Agent (Antifoam A, commercially available
0.05 from Dow Corning) Isocyanate Component (components by weight
%) Isocyanate-prepolymer (liquid, modified short chain 60.00
prepolymer based on pure 4,4'-MDI and having an NCO content of 22.9
wt. %, commercially available from BASF Corporation.) Polymeric
isocyanate (PMDI with a functionality of 40.00 about 2.7 and an NCO
content of 31.5 wt. %, commercially available from BASF
Corporation.) Polymeric Binder Composition Properties:
Resin/Isocyanate Weight Ratio 1.404 Isocyanate Index 121 Tensile
Strength, psi 2,685 Elongation, % 100 Grave's Tear Strength, ppi
426 Durometer Shore Hardness D 56 Peel Strength ppi 75 Tg, .degree.
C. 44
[0017] As mentioned previously, the polymeric binder composition
may be colored to provide a colored composite pavement structure
through the use of a colorant having a first color. By use of the
term "colorant" it is meant to broadly include any type of
colorant, such as pigments, dyes, and combinations thereof.
Non-limiting examples of the first color are red, blue, green,
yellow, brown, black, white, and combinations thereof. Benefits of
using a colored polymeric binder composition are improved aesthetic
appeal of the composite pavement structure and additional UV
protection of the polymeric binder composition. These benefits can
be achieved without a significant reduction in the Solar Reflective
Index (SRI) of the composite pavement structure, as shown in Table
II below.
TABLE-US-00002 TABLE II Solar Reflective Index (SRI) for Pavement
SRI Glass Aggregate Composite Pavement Structures: E1, "Sapphire
Blue" 49 E2, "Topaz Brown" 51 E3, "Sedona Red" 53 E4, "Amber Brown"
61 E5, "Jade Green" 62 E6, uncolored 69 Prior Art Pavement
Structures: New Asphalt 0 Old Asphalt 6 New Concrete 38-52 Old
Concrete 19-32
[0018] As shown in Table I, the colored embodiments of the
composite pavement structures each have excellent SRI values that
are substantially greater than 29. Many colors other than those
listed in Table I are also possible. As compared to prior art
asphalt and concrete pavement structures, a glass aggregate based
colored composite porous pavement structure can provide a more
aesthetically desirable pavement with improved reflectivity. The
SRI values shown in Table I were conducted in accordance with ASTM
E 1980.
[0019] To provide the colored polymeric binder composition, an
inorganic colorant may be provided. If employed, the colorant is
typically a pigment or a pigment blend of two or more pigments. The
pigment, or pigment blend, is used to impart a desired color to the
composite material. Different types of pigments can be used for
purposes of the present disclosure. For example, titanium dioxide
can be used to impart a white color and carbon black can be used to
impart a black color, to the composite material, respectively,
while various blends of titanium dioxide and carbon black can be
used to impart various shades of gray to the composite material.
Examples of suitable grades of carbon black and titanium dioxide
for purposes of the present invention are commercially available
from Columbian Chemicals Company of Marietta, Ga., and DuPont.RTM.
Titanium Technologies of Wilmington, Del., respectively. Other
pigments including, but not limited to, red, green, blue, yellow,
green, and brown, and pigment blends thereof, can also be used to
impart color to the composite material in addition to or
alternative to carbon black and/or titanium dioxide. Examples of
suitable grades of pigments for purposes of the present invention
are commercially available from various companies such as BASF
Corporation and Penn Color, Inc. of Hatfield, Pa. It is to be
appreciated that various blends of the aforementioned colorants,
e.g. pigments, can be used to impart the composite material with
various colors, strengths, and shades.
[0020] If employed in the composite material, the colorant is
typically present in the composite material in an amount suitable
to impart the composite material with a desired color, strength and
shade, while not materially affecting physical properties of the
composite material. In certain embodiments employing the colorant,
the colorant is typically present in the polymeric binder
composition in an amount of from about 0.1 to about 10, and more
typically of from about 0.1 to about 5, parts by weight, based on
100 parts by weight of the binder composition.
[0021] Where the employed colorant is a solid or powder, such as a
dry pigment powder, it is useful to combine the colorant with a
dilutant to form a colorant concentrate that will flow and can be
readily pumped. Where the colorant is an inorganic pigment powder
and the dilutant is a resin, the pigment is present in the colorant
concentrate in an amount of about 10 to about 35 parts by weight,
and more typically about 32 parts by weight, based on 100 parts by
weight colorant concentrate. In some embodiments, the dilutant is
one of the first component or the second component of the polymeric
binder composition. The process of forming the colorant concentrate
may be performed in the field, or more preferably, within a
facility where the environment may be more carefully controlled.
Benefits of preparing the colorant concentrate in a controlled
environment are increased accuracy and the minimization of waste
caused by wind and other field conditions.
[0022] Once formed, the colorant concentrate may be introduced into
the polymeric binder composition. In one embodiment, the colorant
concentrate is first combined with the first component of the
polymeric binder composition. In one embodiment, the colorant
concentrate is first combined with the second component of the
polymeric binder composition. In one embodiment, the colorant
concentrate and the first and second components of the polymeric
binder composition are combined simultaneously. Where the dilutant
matches the first or second components of the polymeric binder
composition, the colorant concentrate is typically combined with
either the component matching the dilutant or combined
simultaneously with both components. Additionally, where the
dilutant matches the first or second components, the amount of
dilutant present in the concentrate is typically taken into account
when determining the volume of the first and second components to
be combined. Once combined, the colorant concentrate and the first
and second components form a colored polymeric binder
composition.
[0023] When the colored polymeric binder composition is mixed with
the glass aggregate particles, the polymeric binder composition
will react and bond with the glass to form a colored composite
material that, once cured, will be a colored composite pavement
structure. As noted above, greater structural strength can be
achieved when using silylated glass aggregate particles. While the
composite material is still workable, the colored composite
pavement structure may be applied to a compacted surface and
subsequently screeded and troweled. Once the polymeric binder
composition has fully cured, the composite pavement structure will
be ready for use.
[0024] After the composite pavement structure has been formed for
about a day, an optional top coating may be applied to the surface
of the structure, as shown in FIG. 4. In one embodiment, the top
coating 18 is a two component modified aliphatic polyurea which
increases the wear performance the colored composite pavement
structure 14, which may be water pervious or porous. The top
coating 18 may be clear or be tinted to match the first color of
the colorant used for the colored composite pavement structure 14.
Where a tinted top coat 18 is used, additional UV protection of the
composite pavement structure 14 is realized. The top coating may be
applied by spraying or rolling. In the embodiment shown, the
composite pavement structure has a thickness 20 of about 1 mil to
about 10 mils, and most preferably of about 5 to about 6 mils. It
should be noted that where the composite pavement structure 14 is
porous, that the thickness of the top coating is not precisely
controllable and that the above identified thicknesses are general
approximations. Examples of suitable top coatings for purposes of
the present disclosure are commercially available from various
companies such as VersaFlex Incorporated of Kansas City, Kans. The
thickness 16 of the composite pavement structure may vary
considerably depending upon the intended application. A thickness
16 of about 2.5 inches to about 3.5 inches is suitable for many
applications.
[0025] With reference to FIGS. 2 and 3, a mixing system 100 for
producing the disclosed colored composite material curable into a
colored composite pavement structure is shown.
[0026] One aspect of the mixing system 100 is aggregate feed system
600. Aggregate feed system 600 is for storing and subsequently
transporting aggregate particles 601 through the mixing system 100.
Many embodiments of the aggregate feed system 600 are possible. In
the exemplary embodiment shown in FIGS. 2 and 3, aggregate feed
system 600 includes an aggregate storage vessel 602. It is to be
appreciated that any type of vessel 602 suitable for holding the
aggregate can be employed. Typically, the aggregate vessel 602
defines a hole 602a. The aggregate vessel 602 also includes a gate
602b, the gate 602b typically being adjacent to the hole. The gate
602b is operable between an open and closed position, such that
when the gate 602b is in the closed position the aggregate is
retained within the aggregate vessel 602, and when the gate is in
the open position, the aggregate exits the aggregate vessel 602
through the hole. It is to be appreciated that the aggregate may
exit the aggregate vessel 602 by other methods known in the art
without departing from the scope of the present invention. If an
additive component is employed, the mixing system 602 can include
an additive vessel (not shown) for holding the additive component.
Alternatively, the additive component may be disposed into at least
one of the aggregate vessels 602.
[0027] Aggregate feed system 600 is also shown as having a conveyer
apparatus 604 and a mixing apparatus 606. Conveyor 604 is for
transporting the aggregate 601 from the aggregate vessel 602 to the
mixing apparatus 606 at a delivery rate in direction 610. In the
particular embodiment shown, conveyor 604 is a belt type conveyor
although other types of conveyors are suitable for this purpose.
Mixing apparatus 606 is for mixing the aggregate with the colored
polymeric binder composition. In the particular embodiment shown,
mixing apparatus 606 is an auger type system including a housing
608 defining a channel within which an auger 610 is rotatably
disposed. The auger 610 includes a shaft with flighting in a spiral
configuration such that the rotation of the auger 610 results in
the composite material moving in direction 612 along the length of
the housing 608. The shaft can also include one or more pins or
fingers for additional mixing. As the composite material is moved
within the channel, the auger 610 mixes the composite material to
increase the surface area of the aggregate exposed to the reaction
product of the polymeric binder composition thereby coating the
aggregate with the reaction product of the binder composition. The
mixing of the composite material by the auger 610 ensures that the
colored composite material produced by the mixing system 20 is
uniform and consistent. As the composite material reaches the end
of the channel, the composite material is dispensed from the
housing 608 at a production rate. One skilled in the art will
appreciate that many other types of aggregate feed systems 600 are
suitable for the above stated purposes.
[0028] The mixing system 100 is shown as further including three
delivery systems: a colorant concentrate delivery system 200, a
first component delivery system 300, and a second component
delivery system 400. Each of the delivery systems 200, 300, 400 is
for storing and delivering the stored component to a mixing system
500, discussed later. Many embodiments of delivery systems 200,
300, 400 are possible without departing from the concepts discussed
herein. As shown, each of delivery systems 200, 300, 400 include a
valve 206, 306, 406 and a pump 208, 308, 408 which deliver the
components to mixing system 500 via lines 204, 304, and 404 from
first, second, and third storage vessels 202, 302, 402,
respectively. In the embodiment shown, storage vessel 202 holds the
colorant concentrate system independently of the first component,
stored in vessel 302, and independently of the second component,
stored in vessel 402. In the embodiment shown in FIG. 2, the
colorant concentrate, the first component and the second component
of the polymeric binder composition are provided to the mixing
system 500 independent of each other, i.e. prior to mixing. FIG. 3
differs from FIG. 2 in that the colorant concentrate is delivered
from vessel 202 to vessel 302 directly rather than to mixing system
500. It is to be appreciated that the colorant concentrate and the
first and second components may be dispensed from the vessels 202,
302, and 402 by any suitable method.
[0029] As stated above, the delivery systems 200, 300, and 400 can
include a pump 208, 308, 408 in fluid communication with the
vessels 202, 302, 402, respectively. The pumps 208, 308, 408
dispense the concentrate and first and second components in an
appropriate ratio as required to form the reaction product of the
two-component polymeric binder composition. If the pumps 208, 308,
408 are employed, the pumps can comprise a motor for rotating the
pumps to control the delivery rate of the respective component.
Each pump 208, 308, 408 may have an integral and/or individual
motor, or the pumps may be mechanically coupled together, such as
by a chain, and driven by a single motor. In the latter case, the
gearing of the couplings can be modified such that the desired
output ratio of components is attained.
[0030] As stated above, delivery systems 200, 300, 400 may also
each include a valve in fluid communication with the mixer 502, as
shown in FIGS. 2 and 3. The valves 206, 306, 406 are operable
between an open position and a closed position and are for
preventing the introduction of air into the mixer 502 when the
mixing system 100 is idle. In the particular embodiment shown,
valves 206, 306, 406 are located between the mixer 502 and the
vessel 202, 302, 402 associated with the valve. It is to be
appreciated that a single valve can be located downstream of the
mixer 502 such that the concentrate and the first and second
components are mixed by the mixer 502 prior to passing through the
valve.
[0031] As stated above, mixing system 100 may further include a
mixing system 500 having a mixer 502 in communication with vessels
202, 302, 402 for mixing the colorant concentrate, the first
component and the second component to produce the colored polymeric
binder composition. The mixer 502, also referred to in the art as a
mix head, intimately mixes the colorant concentrate and the first
and second components to produce the reaction product of the binder
composition. It is to be appreciated that the mixer 502 can be of
any type suitable for mixing the components, such as mechanical
mixers and non-mechanical mixers. For example, in one embodiment,
the mixer 502 is a static mixer for mixing the first and second
components to form the reaction product of the binder
composition.
[0032] Mixing system 500 may also further include an applicator 506
in fluid communication with the mixer 502 via line 504, as shown in
FIGS. 2 and 3. The applicator 506 applies the reaction product of
the binder composition at an application rate to the aggregate
disposed in the mixing apparatus 606. It is to be appreciated that
the mixer 502 may also be the applicator 506. For example, the
mixer 502 may be an impingement mixer, which directs separate
streams of the concentrate and first and second components
component together for mixing the concentrate and first and second
components to form the reaction product of the binder composition
while simultaneously applying the colored reaction product of the
binder composition. Alternatively, applicator 506 may be a sprayer
or a manifold comprising spray heads, as shown in FIGS. 2 and 3.
When applicator 506 is configured as a sprayer, compressed air may
also be provided to aid in the formation of the fluid spray
pattern.
[0033] The mixing system 100 may further include a platform 800 for
holding the components of mixing system 100. At least one of the
aggregate vessel 602, the vessels 202, 302, 042, the conveyor 604,
and the mixing apparatus 606 are typically disposed on the platform
800. Although not required, the mixing system 100 may include the
platform for transporting the mixing system 100 thereby making the
mixing system 100 portable between job sites. It is to be
appreciated that the mixing system 100 may also be transported to
the job site and assembled on the ground or supported by another
structure such that the mixing system 100 is generally
non-portable. In one embodiment employing the platform 800, shown
in FIG. 5, each of the delivery systems 200, 300, 400, 600 are
disposed on a mobile platform 800 having wheels 802. In FIG. 5,
platform 800 is shown as wheeled trailer. Platform 800 may also be
a portion of a flatbed truck or made otherwise mobile.
[0034] The mixing system 100 may be powered by a variety of power
sources. For example, the pumps, conveyor and mixing apparatus may
be activated by electric motors powered by a generator or any other
electrical power source. Alternatively, the equipment may be
powered hydraulically through a PTO system of an engine. Many other
means for powering the mixing system 100 are possible.
[0035] Generally, the aggregate 601 is provided to the mixing
apparatus 606 at a delivery rate and the reaction product of the
colored polymeric binder composition is applied to the aggregate
within the mixing apparatus 606 at an application rate to produce
the composite material. It is to be appreciated that the composite
material is produced once the reaction product of the binder
composition contacts the aggregate. The reaction product can be
formed before, after, or contemporaneously with contacting the
aggregate. The delivery rate is dependent, in part, on an amount of
the composite material the mixing system 100 is to produce.
Likewise, the application rate of the reaction product to the
aggregate is generally dependent on the delivery rate of the
aggregate to the mixing apparatus 606. If the pumps 208, 308, 408
are employed, the pumps can vary the application rate of the
reaction product of the binder composition dependent, in part, on
the delivery rate of the aggregate. Typically, the application rate
of the reaction product to the aggregate is typically of from about
1 to about 7, and more typically from about 1.8 to about 5 gallons
per cubic feet of the aggregate provided into the channel. The
composite material is pliable as it is dispensed from the channel
for allowing the composite material to be shaped into a desired
configuration, i.e. the composite material has sufficient working
time after dispensing. The mixing system 100 is capable of
producing and dispensing the composite material in about 5 to about
15 seconds. This relatively short production time ensures that the
composite material will be pliable for some time after it is
dispensed from the housing 608, typically at least about 10
minutes.
[0036] In order to ensure that the delivery rates, application
rates, production rates, and other rates are optimal, a control
system 700 may be provided. The control system 700 may be
mechanical, electro-mechanical, and/or electronic. In the
embodiments shown in FIGS. 2 and 3, control system 700 includes a
controller 702 configured to monitor and/or control the delivery
rates of the colorant concentrate, the first component, the second
component, the aggregate on conveyor 604, and the composite
material on mixing apparatus 606 via control points C1, C2, C3, C4,
and C5 respectively. In one embodiment controller 702 can control
and receive the delivery rate of the aggregate on the conveyor and
thereby set the output of pumps 208, 308, and 608 to attain the
desired application rate from applicator 506. The controller 702
may control the production rate of the mixing apparatus 606 based
on the sensed or commanded delivery rates and application rates.
One skilled in the art will also appreciate that manual control of
the mixing system 100 is possible.
[0037] The above are example principles. Many embodiments can be
made.
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