WO1990011331A1

WO1990011331A1 - Patch binder and method for road surface repair

Info

Publication number: WO1990011331A1
Application number: PCT/US1990/001620
Authority: WO
Inventors: Paul C. Doran; Paul D. Strickland
Original assignee: Doran Paul C; Strickland Paul D
Priority date: 1989-03-29
Filing date: 1990-03-26
Publication date: 1990-10-04
Also published as: AU5353890A

Abstract

A patch binder (14) for road surface repair is capable of being sprayed under pressure onto existing road surfaces (10, 12, 18, 20, 22) to foster seamless homogenizing and mending of existing road surface material with added asphalt patch material. The patch binder (14) is composed of Toluene, Cyclohexanone, N-methylpyrrolidone, and a black coloration material. It is non-hazardous to humans and to the environment, can be applied independent of weather and climate conditions, and lasts as long as the material of the road surface (10, 12, 18, 20, 22) to which it is applied.

Description

PATCH BINDER AND METHOD FOR ROAD SURFACE REPAIR

Technical Field

The present invention generally relates to road surface repair and, more particularly, is concerned with a patch binder capable of being sprayed under pressure onto a road surface to foster seamless homogenizing and mending of existing road surface material with added patch material.

Background Art

Improvements in road construction have been a prerequisite to progress and growth of civilizations throughout history. The perpetual problem has been how to build and maintain a travelable roadway that will not break down from natural forces of weather and climate, or from use by man-made machines.

From roads constructed with wood blocks, cobble, rocks or brick to those built with macadam (asphalt concrete formed from stone and bitumen), tar, asphalt and concrete, the ever-present pot hole has been the nemesis of the road maintenance engineer. Expansion and contraction of the road surface due to the heat and drying effect of the sun and the coolness of the nights or the winter frost cause cracks and fissures to appear in the road surface into which water seeps, eventually leading to road destruction and wash-out.

With the demand for all-weather roads sparked by the automobile in the early decades of the twentieth century, rigid concrete highways (through the development of Portland cement) and variations of asphalt road material (through the development of the petroleum industry) began to spring up in the United States. By the latter half of this century, a nationwide interstate road system was initiated and developed. Comparable development of highways have occurred in other countries. Constant growth of the petroleum industry along with demands for petroleum asphalt products for road construction fostered continuous research into types of asphalt. Major improvements in road construction equipment and in the road and highway system itself were the outgrowth of the enormous development of asphalt and asphalt-related products. But, as the demand for improved road construction techniques continued to grow, so did the necessity for improvements in road repair and maintenance techniques. However, the latter has never kept pace with the progress of road building science. The pot hole still exists as both the symbol and the reality of this fact.

Over the years, many terms have been assigned to asphalt surfaced roads. There are many synonyms used colloquially and interchangeably. Although these materials and processes differ from one another, it is not unusual to hear the following terms used indiscriminately when describing a black road surface: macadam, blacktop, soft coat, road metal, asphaltic cement, bitumen (surface), shingle, asphalt surface, asphalt road, gilsonite, chip seal, tar, pitch road, paved-low type, pavement, road mix, hot/cold mix, flexible type, intermediate type, and many more.

Technically speaking, asphalt is a native mixture of hydrocarbons which occurs as an amorphous, viscous, brownish-black solid or semisolid. It results from the evaporation of the lighter hydrocarbons from petroleum and partial oxidation of the residue. (Petroleum asphalt differs from tar or pitch , which results from the destructive distillation of coal). Asphalt is insoluble in water, alcohol, acids and alkalies, but soluble in petroleum, chloroform, ether, acetone, carbon disulfide, and oil turpentine.

However, regardless of which descriptive term is applied to the road surface being discussed, the common denominator is that they all need repair. Depending on the type of road surface, the dressing and desiccation of moisture, the proper preparation and handling of the material, the weather and climate conditions, and the traffic type and flow, a road repair may last from only weeks to a few years until the same problem reappears.

Basically, there are two products that have been used previously in the maintenance and repair of road surfaces, one used much more widely than the other. The one product that has seen wide use is "liquid asphalt", commonly called "asphalt medium curing" or "tack oil" (which has carried the commercial designations: MC-30, MC-70, MC-250, MC- 800, and MC-3000).

However, tack oil has many shortcomings making it less than an effective road surface repair product.

In repairing pot holes or filling cracks in existing asphalt road surfaces, tack oil is strictly a "gluing" process or a "tacking" of new asphalt to the old. There is no homogeneous admixture of the new with the old asphalt. This repair leaves seams for water seepage and edges for mechanical displacement. It typically lasts only a few months because of the susceptibility to water seepage and the occurrence of road heaving. The old and new asphalt materials eventually separate and the original problem reoccurs.

Further, weather and climate conditions must be near "perfect" for application of tack oil, which at best allows for only a minimal time until replacement again is necessitated. Tack oil cannot be used in cold or wet weather or on wet surfaces. Also, tack oil repair of road surfaces requires a multiple highway crew to apply the asphalt and the use of expensive equipment. The tack oil must be pre-heated to 250 degrees F for 2-3 hours before application, then applied and the overlaying asphalt rolled or tamped in place to form a smooth surface.

The other product which has seen limited use in the maintenance and repair of road surfaces is called "asphalt bond" (which has carried the commercial designations: H-55 and H-88). Asphalt bond is a chemical formulation of: (1) Toluol or Toluene, Cyclohexanol , N ,N-Dimethylf oramide (DMF), and petroleum soap or surfactant. It is a clear, water-white liquid used for hot asphalt repair bond only. Its chemical formulation is changed (and commercial designation is changed to C-55 ) by removal of the chemical DMF for cold weather asphalt repair application. Asphalt bond does promote seamless homogenizing and mending of existing road surface material with added patch material. However, its DMF constituent is a known hazardous chemical both to human health and the environment. Thus, asphalt bond is unsuitable under governmental regulatory health and safety standards for use in road surface repair applications in particular and in spray applications in general.

Consequently, a long-felt need still exists for a product ef fective in road surface repair applications, whose use is not contingent on weather and climate conditions and does not require extensive equipment to apply it. At the same time, the product must meet all applicable regulatory health and safety standards.

Disclosure of Invention

The present invention provides a road repair or patch binder and repair method designed to satisfy the aforementioned needs. The patch binder of the present invention addresses and resolves the above- described problems ^'of road surface repair and maintenance and avoids the drawbacks of the prior art products. It is a viscous liquid, preferably black in color, capable of being sprayed from a pressure hose. Its application to road surfaces is neither equipment nor labor intensive.

The patch binder of the present invention is basically composed of three chemical constituents: Toluene, Cyclohexanone, and N-methylprrolidone (NMP). A fourth chemical constituent, a dye or coloration material, preferably black in color, can also be incorporated if desired.

Its uses are much broader than the prior art asphalt bond and its the chemical formulation is much different: only two of its chemical constituents were used in the prior art asphalt bond. Unlike the prior art asphalt bond, the patch binder of the present invention softens and penetrates the existing asphalt to create a mending process through homogenizing of the existing asphalt with added asphalt patch material, in either hot or cold state independent of weather and climate conditions, creating a single mass of road surface without seams. Further, unlike the prior art asphalt bond, the patch binder of the present invention is not hazardous to either human health or the environment, is suitable under applicable regulatory health and safety standards for use in road surface repair applications, and can be applied as a spray.

Also, the present invention is directed to a method of repairing a pot hole or a crack or separation in a road surface. The repairing method comprises the steps of: (a) providing a liquid repair patch binder in the form of the above-defined mixture; and (b) applying, such as by spraying, the liquid repair binder on the exposed pot hole or crack and the road surface edge surrounding the same. In repairing a wide separation or a pot hole, the method also comprises the further step of filling and consolidating a repair patch material in the separation or pot hole.

Further, the present invention concerns a method of mending new asphalt filling a utility cut in a road surface with old asphalt bounding the utility cut. The mending method comprises the steps of: (a) providing a liquid repair binder in the form of the above-defined mixture; and (b) applying, such as by spraying, the liquid repair binder on the region of interface between the new and old asphalt to cause homogenizing of the new and old asphalt together.

Still further, the present invention relates to a method of preparing old asphalt of a road surface for mending with new asphalt overlaid on a portion of the old asphalt. The preparing method comprises the steps of: (a) providing a liquid repair patch binder in the form of the above-defined mixture; and (b) applying, such as by spraying, the liquid repair binder on the portion of the old asphalt before the new asphalt is applied thereon. Yet further, the present invention is directed to a method of inhibiting asphalt bleed of an asphalt road surface. The inhibiting method comprises the steps of: (a) providing a liquid repair patch binder in the form of the above-defined mixture; (b) applying, such as by spraying, the liquid repair binder on the asphalt road surface; and (c) thereafter, depositing sand on the liquid repair binder applied on the asphalt road surface. The present invention also relates to a method of resurfacing an asphalt road surface. The resurfacing method comprises the steps of: (a) providing a liquid repair binder in the form of the above-defined mixture; (b) applying, such as by spraying, the liquid repair binder on the asphalt road surface; and (c) thereafter, depositing a chipping material on the liquid repair binder applied on the asphalt road surface.

Brief Description of Drawings Fig. 1 is a schematical representation of an existing road surface containing a pot hole.

Fig. 2 is a schematical representation of the existing road surface and pot hole of Fig. 1 with the patch binder of the present invention applied thereto.

Fig. 3 is a schematical representation of the existing road surface and pot hole of Fig. 1 with the patch binder applied thereto as seen in Fig. 2 and with added repair asphalt filling the pot hole and covering the patch binder to provide seamless homogenizing and mending of the old asphalt with the added repair asphalt. Best Mode for Carrying Out the Invention

Referring now to the drawings, and particularly to Fig. 1, there is shown a typical pot hole 10 in a road surface 12. The patch binder of the present invention, as schematically represented at 14 in Fig. 2, is highly advantageous in its ability to promote repair of pot holes, such as the pot hole 10 in the road surface 12 depicted in Fig. 1. However, it can be used on other surfaces, such as curbs and gutters, parking lots, driveways, airport runways and roofs, as an asphalt crack filler, curb and gutter bonder and sealer, road overlay, concrete joint filler, asphalt bleed inhibitor, soil sealant to inhibit seepage, and roof patch. The patch binder 14 is a viscous liquid, capable of being sprayed from a pressure hose 16 on the surface to be repaired. For instance, as represented in Fig. 2, it is sprayed on the sides 18 and bottom 20 of the pot hole 10 and the edges 22 of the original road surface 12 surrounding the pot hole 10. When applied to the existing asphalt of the pot hole 10 and road surface 12, the patch binder 14 softens and penetrates the asphalt. Then, when either hot or cold asphalt patch material 24 is added to fill the pot hole 10 and overlap the road surface edge 22, the patch binder 14 fosters a mending process through homogenizing of the existing asphalt with the added patch asphalt , creating a single mass of reconstituted road surface without seams. The patch binder 14 of the present invention is preferably composed of the chemical constituents listed in Table I. In applications where color is unimportant, the coloration material can be omitted. The CAS numbers and preferred approximate proportions in percentage by weight of the chemical constituents are also given in the table.

Table I

Chemical Constituent CAS# Percentages

Toluene 108-88-3 67 66

Cyclohexanone 108-91-1 15 16

N-methylpyrrolidone (NMP) 872-50-4 17 18 Black dye or coloration material trace trace

(The percentages by weight of the chemical constituents can vary within ranges which include the preferred listed percentages. For example. Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N- methylpyrrolidon , from 17 to 18; and the trace of black dye.

The Toluene constituent is a chemical solvent, typically used in glues, paints, fingernail polish remover, and cleaning fluids. It is an aromatic hydrocarbon , also known as methylbenzol , ethylbenzene and phenylmethane .

The Cyclohexanone constituent is a low cost solvent, typically used in lacquers, resins and insecticides, and also used for metal degreasing. It is also known as pimelic ketone , cyclohexol ketone and ketohexamethylene.

The N-methylpyrrolidone (NMP) constituent is a solvent used extensively in chemical processing, particularly in petroleum refining. It is also important as a solvent in agricultural chemical formulation and is used as a chemical intermediate in the pharmaceutical industry and used in the cosmetic industry as a vehicle and to promote penetration of other compounds into the formulation.

The black dye or coloration constituent, when incorporated, is a preferably a compatible black petroleum product, such as liquid asphalt, to create a black color to an otherwise clear formulation. This is necessary for maintaining familiarity and acceptance by end users having years of experience associating asphalt roadways with a black color as well as for allowing visualization of the spray from a hose onto the applied surface. In applications where other colors are desired, other coloration materials could be used. In addition to pot hole repair, the patch binder 14 is equally applicable to many other uses in place of tack oil which was previously used. One use of the binder 14 is to repair, i.e., seal, separations or cracks in road surfaces and other surfaces (mentioned earlier) also. The repair method is carried out by applying the liquid repair binder on the exposed crack and on the road surface edge surrounding the crack. Depending on the width of the crack, it may or may not need to be filled with a repair patch material. Another use is the mending of new asphalt that fills a utility cut in a road surface with old asphalt bounding the utility cut. The mending method is carried out by applying the liquid repair binder on the region of interface between the new and old asphalt which causes homogenizing of the new and old asphalt together. Yet another use is the preparing of old asphalt of a road surface for mending with new asphalt overlaid on a portion of the old asphalt. The preparing method is carried out by applying the liquid repair binder on the portion of the old asphalt, then depositing the new asphalt on the applied repair binder. Still another use is the inhibiting of asphalt bleeding of an asphalt road surface. The inhibiting method is performed by applying the liquid repair binder on the asphalt road surface and, thereafter, depositing sand on the applied liquid repair binder. A further use is the resurfacing an asphalt road surface. The resurfacing method is carried out by applying the liquid repair binder on the asphalt road surface and, thereafter, depositing a chipping material on the applied liquid repair binder.

To recapitulate, the features and advantages of the patch binder of the present invention are as follows: (a) non-hazardous to human beings and to the environment by spraying, atomizing, dripping, pouring, or the like onto a repair surface; (b) has long life on the road surface, lasting indefinitely, as long as the original asphalt surface; (c) homogenizes into existing asphalt surface to allow no seams, with the edges of repair asphalt (hot or cold) feathered into existing road surface; (d) does not permit water or moisture to undermine the repair hot or cold asphalt due to lack of seams or edges; (e) can be used in all temperatures and with either hot asphalt or cold asphalt repair material; (f) needs minimal to no road dressing or desiccation of moisture; (g) requires minimum work crew of 1-2 workers for application; (h) requires no preheating to apply; (i) requires no expensive equipment, does not need heating or boiler equipment, and eliminates propane heating gas; and (j) minimizes manpower skill level required and total expense in manpower and equipment. It is thought that the present invention and many of its attendant advantages will be understood from the foregoing description and it will be apparent that various changes may be made in the form, construction and arrangement of the parts thereof without departing from the spirit and scope of the invention or sacrificing all of its material advantages, the forms hereinbefore described being merely preferred or exemplary embodiments thereof.

Claims

Claims 1. A mixture for use as a repair patch binder, characterized by:

(a) Toluene, in the percentage by weight range of 66 to 80;

(b) Cyclohexanone, in the percentage by weight range of 15 to 22; and

(c) N-methylpyrrolidone, in the percentage by weight range of 17 to 18.

2. The mixture as recited in Claim 1, further characterized by:

(d) a trace of coloration material.

3. The mixture as recited in Claim 2, wherein said coloration material is black in color.

4. The mixture as recited in Claim 1, wherein said chemical constituents of said repair patch binder are in the following approximate percentages by weight: Toluene - 66; Cyclohexanone - 16; and N- methylpyrrolidone - 18.

5. The mixture as recited in Claim 1, wherein said chemical constituents of said repair patch binder are in the following approximate percentages by weight: Toluene - 67; Cyclohexanone - 15; and N- methylpyrrolidone - 17.

6. A method of repairing a pot hole in a road surface, characterized by the steps of:

(a) providing a liquid repair binder in the form of a mixture having the chemical constituents. Toluene, Cyclohexanone, and N-methylpyrrolidone; (b) spraying the liquid repair binder on the exposed surface of the pot hole and road surface edge surrounding the pot hole; and

(c) filling and consolidating in the pot hole a repair patch material.

7. The repairing method as recited in Claim 6, wherein said mixture providing said liquid repair binder also includes a coloration material.

8. The repairing method as recited in Claim 7, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges : Toluene , from 66 to 80 ; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.

9. The repairing method as recited in Claim 7, wherein said coloration material is black in color.

10. The repairing method as recited in Claim 7, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight: Toluene - 66; Cyclohexanone - 16; N- ethylpyrrolidone - 18; and a trace of coloration material.

11. The repairing method as recited in Claim 7, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight: Toluene - 67; Cyclohexanone - 15; N- methylpyrrolidone - 17; and a trace of coloration material.

12. A method of repairing a separation in a road surface, characterized by the steps of: (a) providing a liquid repair binder in the form of a mixture having the chemical constituents. Toluene, Cyclohexanone, and N-methylpyrrolidone; and

(b) applying the liquid repair binder on the exposed separation and the road surface edge surrounding the separation.

13. The repairing method as recited in Claim 12, wherein said mixture providing said liquid repair binder also includes a coloration material.

14. The repairing method as recited in Claim 13, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges: Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.

15. The repairing method as recited in Claim 12, further characterized by the step of:

(c) filling and consolidating in the separation a repair patch material.

16. A method of mending new asphalt filling a utility cut in a road surface with old asphalt bounding the utility cut, characterized by the steps of:

(a) providing a liquid repair binder in the form of a mixture having the chemical constituents, Toluene, Cyclohexanone, and N-methylpyrrolidone; and

(b) applying the liquid repair binder on the region of interface between the new and old asphalt to cause homogenizing of said new and old asphalt together.

17. The mending method as recited in Claim 16, wherein said mixture providing said liquid repair binder also includes a coloration material.

18. The mending method as recited in Claim 17, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges: Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.

19. A method of preparing old asphalt of a road surface for mending with new asphalt overlaid on a portion of the old asphalt, characterized by the steps of:

(a) providing a liquid repair binder in the form of a mixture having the chemical constituents, Toluene, Cyclohexanone, and N-methylpyrrolidone; and (b) applying the liquid repair binder on the portion of the old asphalt before the new asphalt is applied thereon.

20. The preparing method as recited in Claim 19, wherein said mixture providing said liquid repair binder also includes a coloration material.

21. The preparing method as recited in Claim 20, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges: Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.

22. A method of inhibiting asphalt bleed of an asphalt road surface, characterized by the steps of: (a) providing a liquid repair patch binder in the form of a mixture having the chemical constituents . Toluene , Cyclohexanone, N- methylpyrrolidone, and a coloration material;

(b) applying the liquid repair binder on the asphalt road surface; and

(c) thereafter, depositing sand on the liquid repair binder applied on the asphalt road surface.

23. The inhibiting method as recited in Claim 22, wherein said mixture providing said liquid repair binder also includes a coloration material.

24. The inhibiting method as recited in Claim 22, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges: Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.

25. A method of resurfacing an asphalt road surface, characterized by the steps of:

(a) providing a liquid repair binder in the form of a mixture having the chemical constituents. Toluene, Cyclohexanone, and N-methylpyrrolidone; and

(b) applying the liquid repair binder on the asphalt road surface; and

(c) thereafter, depositing a chipping material on the liquid repair binder applied on the asphalt road surface.

26. The resurfacing method as recited in Claim

25, wherein said mixture providing said liquid repair binder also includes a coloration material.

27. The resurfacing method as recited in Claim

26, wherein said chemical constituents of said liquid repair binder are in the following percentages by weight ranges: Toluene, from 66 to 80; Cyclohexanone, from 15 to 22; N-methylpyrrolidone, from 17 to 18; and a trace of coloration material.