ASPHALT BRICK DEVICE AND METHOD OF MAKING SAME

Abstract

The present invention provides an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities, as provided in the present invention. An additional aspect of the present invention is to provide an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Further, the asphalt brick device may be configured to be stackable to satisfy user-defined asphalt repair delivery and ordering requirements.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application cross-references U.S. patent application Ser. No. 12/651,358 filed Dec. 31, 2009 entitled “Infrared Heating System and Method for Heating Surfaces,” U.S. patent application Ser. No. 13/167,888 filed Jun. 24, 2011 entitled “Asphalt Repair System and Method,” U.S. patent application Ser. No. 13/742,928 filed Jan. 16, 2013 entitled “System and Method for Sensing and Managing Pothole Location and Pothole Characteristics,” and U.S. patent application Ser. No. 13/777,633 filed Feb. 26, 2013 entitled “System and Method for Controlling an Asphalt Repair Apparatus,” the disclosures of each are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

Embodiments of the present invention are generally related to roadway maintenance and repair, and, in particular, to an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities.

BACKGROUND OF THE INVENTION

Roadway repair and maintenance are a ubiquitous problem that impose financial obligations on roadway authorities and present annoyances, if not costly hazards, to motorists. Asphalt surfaces, such as roads, driveways and parking lots, may suffer damage through a combination of infiltrating and freezing water and the continuous impact from moving vehicles. For example, potholes are a recurring problem creating inevitable damage to roadway surfaces from traffic, construction, and the environment. The enormous number and variety of paved roads makes it difficult for federal, state, and local municipalities to implement repairs in a timely, cost effective and safe manner.

The repair of damaged asphalt roadways generally requires bulk asphalt. The bulk asphalt is conventionally made by mixing and heating an aggregate with a bituminous material. The aggregate may include materials such as crushed stone, gravel, sand, silt and clay. The bituminous material serves as a binding agent. The mixed aggregate and bituminous material is typically heated to a temperature in the range of 250-325° F.

The use of bulk asphalt presents several challenges resulting in inefficiencies and varying effectiveness. For example, the bulk mixture of asphalt is typically mixed and heated at some distance from the application site and transported by a dump truck. Because the asphalt is a loose mixture, the precise quantity of bulk asphalt required for a particular surface repair or construction project can be difficult to determine. Too little delivered bulk asphalt results in one or more additional dump truck trips with resulting idle repair crew time. Too much asphalt results in unnecessary transport costs. Furthermore, the loose mixture of heated bulk asphalt is generally difficult to store, handle and transport.

Bulk asphalt is conventionally manufactured in imprecise compositions of aggregate and bituminous material or in compositions ill-suited for a particular repair site or repair application. For example, bulk asphalt used in a parking lot preferably uses larger-sized (cheaper) aggregate versus a roadway, because a parking lot experiences less loading and wear than a roadway. Also, a repair site exposed to extreme temperature cycles or ranges, such as a Texas highway, require more binding bituminous material than a roadway site with more uniform temperatures, such as a highway within a mountainous tunnel in Utah. Currently, such dissimilar repair sites are typically provided with similar bulk asphalt compositions which is ineffective when applied over a broad range of applications. The economic efficiency, and the effectiveness, of asphalt repairs could be increased if the bulk asphalt were provided in predictable and readily-varied compositions that are fine-tuned and customized to specific repair site conditions and characteristics.

Some efforts have been made to improve the process of asphalt maintenance and repair. For example, U.S. Pat. No. 5,827,008 to Smith et al. (“Smith”) discloses a pavement repair structure and method of repair for forming a bond between vertical surfaces in asphalt pavement. The repair structure comprises a flexible, internal layer that is impregnated with an adhesive asphalt medium to define an elongated strip. An additive agent is incorporated in the asphalt medium to reduce the tackiness and lower the temperature sensitivity of the asphalt medium. A cut in the asphalt pavement caused by either a saw or a jack hammer is sealed by using the repair structure to form a bond between the vertical cut edge of the pavement and the patch of new asphaltic concrete mix. However, Smith fails to teach several novel features of the present invention, including an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Smith is incorporated herein by reference in its entirety.

U.S. Pat. No. 5,556,225 to Marino (“Marino”) discloses a method of repairing multiple backfilled utility cut trenches, potholes, and other discontinuities in asphalt pavement in which the pavement discontinuity is bridged by layers of heated virgin bituminous concrete of different grades, each layer including aggregate stone mixed with a liquid asphalt binder. Alternatively, substantially non-polymerized thermoplastic bituminous concretes of different grades may be used to form the bridging layers, each layer including aggregate stone mixed with a liquid asphalt binder and preferably also containing fractions of n-pentane soluble asphalts and being repetitively softenable in response to repetitive applications of infrared radiation. However, Marino fails to teach several novel features of the present invention, including an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Marino is incorporated herein by reference in its entirety.

European Pat. Appl. No. 2,213,799 to Mainenti (“Mainenti”) discloses a block for repairing a road surface wherein the block includes at least one portion of pre-compressed asphalt. A method for the production of a block suitable for repairing an asphalt road surface comprises the steps of prearranging a mold having a shape corresponding to the portion of pre-compressed asphalt to be obtained; pouring into the mold a mass of asphalt; subjecting the mass to compression, so as to obtain the portion of pre-compressed asphalt, and removing the portion from the mold. However, Mainenti fails to teach several novel features of the present invention, including an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Mainenti is incorporated herein by reference in its entirety.

U.S. Pat. No. 4,684,288 to Chapa (“Chapa”) discloses a pavement tile comprising a section of reinforcing geotextile fabric coated on a top side with asphalt adhesive and a layer of asphalt aggregate mix or “hot mix” over the adhesive. The asphalt aggregate mix is compacted to a desired thickness and degree of compaction. Asphalt is applied over a bottom side of the fabric, and a peelable backing applied over the asphalt. For repair of deteriorated pavement, the protective backing is peeled off, and the pavement tile applied over the deteriorated spot of wear course. New paved surface or large repairs can be made by simply adjoining tiles. The tiles are preferably made in batches. A large sheet is spread with the layers of asphalt adhesive and asphalt aggregate mix, and compacted. The large sheet is cut into tiles, and the asphalt and backing applied to individual tiles. However, Chapa fails to teach several novel features of the present invention, including an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Chapa is incorporated herein by reference in its entirety.

Effective and efficient repair of asphalt roadway surfaces using bulk asphalt could be significantly enhanced if the bulk asphalt was provided in predictable and readily-varied compositions that reflect the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Thus, there is a long-felt need for an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities, as provided in the present invention. An additional aspect of the present invention is to provide an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Further, the asphalt brick device may be configured to be stackable to satisfy user-defined asphalt repair delivery and ordering requirements. The asphalt brick device and method of manufacture provides several benefits, to include providing a more effective and efficient repair of asphalt roadways thereby yielding a more cost and time effective utilization of material, labor, and equipment. For example, the ease of measuring the quantity of bulk asphalt required for a particular job and the ease of handling the asphalt brick device reduces labor time on site.

SUMMARY OF THE INVENTION

It is thus one aspect of the present invention to provide an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities, as provided in the present invention. An additional aspect of the present invention is to provide an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Further, the asphalt brick device may be configured to be stackable to satisfy user-defined asphalt repair delivery and ordering requirements.

In one aspect of the invention, an asphalt brick device having a predetermined shape is disclosed, the asphalt brick device having a predetermined shape comprising: a body having an upper surface, a lower surface, a front surface and a rear surface to define a specific shape; wherein the body comprises an aggregate and a binding agent of a user-selected relative proportion by one of volume and of weight based on pre-determined calculations; wherein the aggregate and binding agent are mixable when the body is in a first state; wherein when the asphalt brick device is adapted to be transportable and stacked.

In another aspect of the invention, a method for manufacturing a portable asphalt brick device having a predetermined shape and consistency is disclosed, the method comprising: receiving a quantity of aggregate and a quantity of binding agent based on a pre-determined location of ultimate use; heating the quantity of aggregate and the quantity of binding agent to a first temperature to form an asphalt mix; mixing the asphalt mix to obtain a substantially uniform composition; compressing the asphalt mix into a mold; forming at least one portable asphalt brick device in the mold; and cooling the at least one portable asphalt brick device below a second temperature.

In a further aspect of the invention, a method of using a preformed portable asphalt brick device to repair a road deformity is disclosed, the method comprising: determining the composition of the preformed portable asphalt brick device based on a geographic location of the road deformity; ordering the preformed portable asphalt brick device; manufacturing the asphalt brick device by mixing at least an aggregate material and a binding agent; forming a shape of the preformed portable asphalt brick device; transporting the preformed portable asphalt brick device to the repair site; heating the preformed portable asphalt brick device to form a paving repair substance; and repairing the repair site using the paving repair substance.

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

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

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

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

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

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

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

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

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

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6.

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

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

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

BRIEF DESCRIPTION OF THE DRAWINGS

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

FIG. 1A is a front perspective view of an asphalt brick device according to one embodiment of the invention;

FIG. 1B is a front elevation view of an asphalt brick device according to another embodiment of the invention;

FIG. 1C is a front elevation view of an asphalt brick device according to yet another embodiment of the invention;

FIG. 2 is a front perspective view of a mold system used to manufacture asphalt brick devices;

FIG. 3 is a flow diagram of an embodiment of a method for manufacturing asphalt brick devices; and

FIG. 4 is a flow diagram of an embodiment of a method for repairing an asphalt site using asphalt brick devices.

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

DETAILED DESCRIPTION

FIGS. 1-4 show various aspects and embodiments of asphalt brick device 2 of the present invention. Asphalt brick devices 2 may be used for repairing an asphalt site such as a roadway. A user may manufacture asphalt brick devices according to site-specific repair requirements.

Referring to FIG. 1A, an asphalt brick device 2 is depicted comprising upper surface 4, lower surface 6, left side 8, right side 10, front 12 and rear 14. Asphalt brick device 2 comprises length L, height H and width W. Further, each of upper surface 4 and lower surface 6 comprise a non-uniform surface or textured surface, such as the waffle pattern depicted.

Referring to FIG. 1B, a front elevation view of an alternate embodiment of an asphalt brick device 2 is depicted. The asphalt brick device 2 comprises upper surface 4, lower surface 6, left side 8, and right side 10. Furthermore, the asphalt brick device comprises a stackable feature: a rectangular protrusion 16 on upper surface 4 and matching rectangular void 18 on lower surface 6. The rectangular void 18 is configured to engage the matching rectangular protrusion 16 of a second asphalt brick device 2 mounted on top of a first asphalt brick device 2. Stated another way, the rectangular void 18 is a conforming void with respect to the rectangular protrusion 16.

Referring to FIG. 1C, a front elevation view of another alternate embodiment of an asphalt brick device 2 is depicted. The asphalt brick device 2 comprises upper surface 4, lower surface 6, left side 8, and right side 10. Furthermore, the asphalt brick device comprises a stackable feature: a large rectangular void 18 with two adjacent small rectangular protrusions 16 on upper surface 4 and matching large rectangular protrusion 16 and two adjacent small rectangular voids 18 on lower surface 6. The large rectangular void 18 is configured to engage the matching large rectangular protrusion 16 of a second asphalt brick device 2 mounted on top of a first asphalt brick device 2.

The asphalt brick device 2 is of a precise quantity of material and is configured to be readily stackable and easily handled. The asphalt brick device 2 is of composition useful for the repair or reconstruction of asphalt roadways, and is sized according to user requirements. For example, in one embodiment, the asphalt brick device 2 is sized to provide one 5- or 10-pound unit of paving repair material, such as an asphalt mix. The asphalt brick device 2 is brick-shaped, as depicted in FIG. 1A, with length L of approximately 12 inches, width W of approximately 8 inches, and height H of approximately 4 inches.

In one embodiment, each side of the asphalt brick device 2 is substantially smooth or uniform. In another embodiment, one or more sides of the asphalt brick device 2 are textured. The textured side(s) may be useful for locking asphalt brick devices 2 together when stacked, which, among other things, provides stability to the stack of asphalt brick device 2 and helps to ensure safety of the stack. For example, the textured side(s) may be advantageous when storing and/or transporting asphalt brick device 2 as it may prevent movement when asphalt brick device 2 are stacked on, for example, a pallet. In one embodiment, the upper surface 4 and lower surface 6 comprise any type of texture or three-dimensional pattern suitable for providing a locking function when stacked, as known to those skilled in the art.

In another embodiment, matching tongue and groove patterns may be used on respective upper surface 4 and lower surface 6. For example, the upper surface 4 of asphalt brick device 2 comprises at least one tongue feature while the lower surface 6 of asphalt brick device 2 has at least one groove feature. When stacked, the tongue feature of one asphalt brick device 2 is fitted into the groove feature of another asphalt brick device 2.

In a further embodiment, the asphalt brick device 2 comprises a void configured such that conventional tines of a forklift may fit or conform to the void. Stated another way, a conforming void may be formed on the asphalt brick device 2, for example, on the lower surface 6, to engage one or more tines of a forklift.

In one embodiment, the weight of the asphalt brick device 2 does not exceed regulatory standards for handling, such as those that may exist by OSHA. In one embodiment, the weight of the asphalt brick device 2 does not exceed 40 lbs.

In another embodiment, the asphalt brick device 2 is fitted with one or more handles for ease of carrying by an individual or a machine such as a forklift. In another embodiment, a plurality of asphalt brick devices 2 are assembled in a wrap, such as plastic wrap similar to that used, for example, when wrapping furniture for moving, so as to allow ready transport of the plurality of asphalt brick devices 2. In one embodiment, a plurality of asphalt brick devices 2 are transported together to form an integer or known quantity of bulk asphalt, e.g. a 1/10 cubic yard of asphalt.

In another embodiment, the asphalt brick device 2 is scored on one or more surfaces to enable a substantially controlled breaking of the asphalt brick device 2 into two or more pieces substantially along an axis aligned with the scored portion. In this manner, a more accurate on-site means to measure and/or dispense a quantity of asphalt is provided. In one embodiment, the scored portion is disposed on at least one of the upper surface and the lower surface of the asphalt brick device 2, the scored portion enabling a substantially controlled breaking of the body into two pieces substantially along an axis aligned with the scored portion.

In one embodiment, the asphalt brick device 2 is marked by alphanumeric for identification of properties, such as weight, type, composition, and date of manufacture. In one embodiment, the asphalt brick device 2 is marked by shape and/or color to identify properties, such as weight, type, composition, and date of manufacture.

In another embodiment, the asphalt brick device 2 comprises one or more sensors that measure or monitor asphalt and/or roadway state. For example, a sensor may be a positional sensor that measures location in one or more dimensions, pressure in one or more axes, temperature, and/or stress/strain. The sensor may be active in that it transmits its measurement, or passive in that only when pulsed or queried sensed data is provided. The sensor may be a fine particle, for example, a nanoparticle. In such a manner, the asphalt brick device 2, once used as part of an asphalt repair job, provides an embedded in-situ sensor at the job site. After placement, the in-situ sensor may be calibrated with respect to initial condition, to include, for example, position, orientation, temperature and pressure. A change in any of these initial condition readings may be used to assess the roadway condition and identify any new and/or returning roadway anomalies. For example, a sensor which translates in a vertical direction beyond a selectable threshold may indicate that a pothole has formed or has returned. Similarly, an increase in recorded pressure beyond a selectable threshold may indicate adjacent roadway compression such as caused by a nearby rut. Such a sensor-equipped asphalt brick device 2 may be used as part of a broader system for sensing and managing pothole locations and pothole characteristics, as provided in U.S. patent application Ser. No. 13/777,633.

Referring to FIG. 2, a front elevation view of a mold system 20 used to manufacture a plurality of asphalt brick devices 2. Mold system 20 comprises lid 24, base 30 and frames 22. Lid 24 comprises upper surface 26 and lower surface 28. Base 30 comprises upper surface 32. Upper surface 32 of base 30 may feature a textured surface, as depicted in FIG. 2.

The base 30 is configured to secure one or more frames 22, and is adaptable in that one or more frames 22 may be removed. FIG. 2 depicts an arrangement of eight (8) frames 22. Each frame 22 is configured to hold a user-selected quantity of unmixed aggregate and binding agent, or a user-selected quantity of mixed aggregate and binding agent. In one embodiment, each frame 22 is configured to allow in-situ mixing of unmixed aggregate and binding agent, and heating and/or cooling of mixed or unmixed aggregate and binding material.

The shape of each frame 22 is configured to form a particular shape of asphalt brick device 2. For example, to form brick-shaped asphalt brick devices 2, each frame 22 has a rectangular box shape, as depicted in FIG. 2. However, asphalt brick device 2 is not limited to brick-like shapes. That is, asphalt brick device 2 can be any shape that allows asphalt brick device 2 to be efficiently stacked and/or handled. Asphalt brick device 2 may be, for example, brick-shaped, pie-shaped, disc-shaped, and those shapes as depicted in FIGS. 1B-C.

Lid 24 and/or base 30 may comprise textured surfaces so as to impart texture to the asphalt brick device 2 contained within a particular frame 22. For example, base 30 may comprise a textured pattern, such as a waffle pattern as depicted in FIG. 2, on the upper surface 32, which would impart the waffle pattern to the lower surface 6 of a particular asphalt brick device 2. The weight of the material contained within a given frame 22 would effect the pattern to the lower surface 6. Further, lid 24 may comprise textured surfaces so as to impart texture to the asphalt brick device 2 contained within a particular frame 22. That is, lid 24 may comprise a textured pattern on lower surface 28. When the lid 24 is pressed against a particular frame substantially filled with material such as aggregate and binding agent, the pressure, that is the compression, between base 30 and lid 24 to the material contained within the frame 22 will effect the textured pattern to the upper surface 4 of the asphalt brick device 2.

The lid 24 and/or the base 30 may also comprise geometries so as to form non-planar surfaces on, respectively, the upper surface 4 and the lower surface 6 of an asphalt brick device 2 formed within a particular frame 22. That is, to form, for example, the asphalt brick device 2 of FIG. 1B, the lid 24 would comprise the rectangular protrusion 16 and the base 30 would comprise the matching rectangular void 18.

In one embodiment, each of the lid 24 and the base 30 do not comprise a uniform pattern or geometry on lower surface 28 and upper surface 32, respectively, such that different shapes and/or patterns may be formed on one or more of the asphalt brick devices 2 formed in a plurality of frames 22. Stated another way, a particular frame 22 may be fitted over an upper surface 32 of a portion of the base 30 with a textured pattern, while an adjacent frame 22 may be fitted over an upper surface 32 of an adjacent portion of the base 30 devoid of a textured pattern. Thus, one asphalt brick device 2 would be formed with a textured bottom surface 6 and another would be formed with a uniform or non-textured bottom surface 6.

In another embodiment, one or more interior surfaces of one or more frames 22 comprise a non-stick material such that a completed asphalt brick device 2 may be more readily removed. Such a non-stick material may be any such material known to those skilled in the art that will urge a mixed aggregate and binding material composition from adhering to a mold.

In one embodiment, the mold 20 is manufactured of materials comprising metals, metal alloys and aluminum. In one embodiment, one or more interior surfaces of a frame 22 of the mold 20 comprise texture and/or a pattern which may urge the removal of an asphalt brick device 2 from a frame 22.

Asphalt brick device 2 is comprised of aggregate and binding agent in selectable relative proportions by one of volume and of weight. Further, the aggregate may be of selectable screen size with a given tolerance or a combination of selectable screen sizes with a given tolerance.

In one embodiment, the asphalt brick device 2 is hot mix asphalt concrete (HMA or HMAC) that is molded into the shape of a brick. HMA is a combination of different sized aggregates and asphalt cement, which binds the mixture together. HMA is generally composed of from about 93% to about 97% by weight of aggregate and from about 3% to about 7% asphalt cement. Table 1 provides examples of the composition of asphalt according to Asphalt Emulsion Handbook, Suit-Kote Corp, pg. 34. For example, asphalt brick device 2 may have a range of 4.5-7.8% bituminous material with the remainder aggregate. Examples of aggregate include, but are not limited to, crushed stone, gravel, sand, silt, and clay.

In other embodiments, the asphalt brick device 2 is any asphalt concrete known to those skilled in the art, to include HMA, warm mix asphalt concrete (WMA), cold mix asphalt concrete, and mastic asphalt concrete or sheet asphalt. In some embodiments, the asphalt brick device 2 comprises recycled rubber (e.g. styrene butadiene styrene), recycled tires, recycled asphalt (RAP), and alternative binders or polymers.

In one embodiment, the asphalt brick device 2 operates in a first state and a second state, in which the first state is a moldable or mixable state and the second state is a substantially solid state. The second state may be at a lower temperature than the first state. The second state may be adapted to be readily transportable and further, may be heated to form a paving repair substance.

TABLE 1
Example formulations of asphalt suitable
for forming asphalt brick device 2
	Type 4	Type 5	Type 6
Mixture	General limits	General limits	General limits
requirements1	percent passing	percent passing	percent passing
Screen sizes	and tolerance1	and tolerance1	and tolerance1
50	mm (2″)
37.5	mm (1½″)	100 —
25	mm (1″)	95-100 —	100 —
12.5	mm (½″)	70-90 ± 6	90-100 —	100
6.3	mm (¼″)	48-74 ± 7	20-70 ± 7	90-100
3.2	mm (⅛″)	32-62 ± 7	15-70 ± 7	30-70 ± 7
0.85	mm (#20)	10-40 ± 7	10-40 ± 7	10-40 ± 7
0.425	mm (#40)	5-22 ± 7	5-22 ± 4	5-22 ± 4
0.180	mm (#80)	1-7 ± 3	1-9 ± 4	1-11 ± 4
75	μm (#200)	0-3 ± 2	0-3 —	0-3 —
Bituminous	4.5-7.0	6.2-7.5	6.5-7.8
materials2,3
Typical uses	Dense-graded	Dense-graded	Dense-graded
	Intermediate	Truing &	Fine top
	course	leveling	course
Source: Adapted from Asphalt Emulsion Handbook, Suit-Kote Corp., page 34
1Percentage based on total aggregate weight.
2Total emulsion percentage based on total mix weight. Residue percentage is determined by multiplying emulsion percentage by asphalt content percentage of the emulsion.
3When crushed air-cooled blast furnace slag is selected, the above bituminous material content shall be increased approximately 25 percent.
Dense-graded mixes are best if mixed using high quality, fractured coarse and fine aggregate to ensure good stability of the produced mix.

An embodiment of a method 40 for manufacturing asphalt brick devices 2 is shown in FIG. 3. A general order for the steps of the method 40 is shown in FIG. 3. Generally, the method 40 starts with a start operation 42 and ends with an end operation 52. The method 40 can include more or fewer steps or can be arranged in a different sequence than those shown in FIG. 3.

At a step 44, a quantity of aggregate and a quantity of binding agent (such as a bituminous material) are received and heated. The relative quantities of aggregate and binding agent, and the type(s) of aggregate and binding agent(s), are selectable. For example, the quantities and/or proportions may be selected from Table 1. The binding agent and aggregate are heated to a first temperature such that the binding agent and aggregate may be mixed to form a substantially uniform composition. In one example, the mixture includes about 5% bituminous material and about 95% gravel by weight. The aggregate and bituminous materials are heated to a temperature of from about 250° F. to about 325° F. and mixed to create a substantially uniform asphalt mixture, i.e. an asphalt concrete, which is moldable and with sufficient viscosity to be able to be poured into a mold. In one embodiment, the first temperature is about 250 degree F. The method then proceeds to step 46.

At a step 46, a selectable amount of the asphalt mixture produced in step 44 is poured into one or more mold frames 22 of a mold 20 and packed as required. The selectable amount of asphalt material poured or delivered into a given mold frame 22 may vary so as to ultimately provide a selectable amount of finished asphalt brick device 2. In one embodiment, the selectable amount of asphalt mixture provided to a plurality of mold frames 22 is not uniform between the mold frames 22. Stated another way, the amount of asphalt mixture is not the same among all of the mold frames 22. In one embodiment, the selectable amount of the asphalt mixture provided to one or more mold frames 22 is suitably precise such that when packed or compressed there is substantially no excess material. The method then proceeds to step 48.

At a step 48, the asphalt mix provided and/or packed into one or more mold frames 22 is allowed to cool from the first temperature of step 44 to a second temperature so as to form one or more solid asphalt brick devices 2. In one embodiment, the second temperature is room temperature. In one embodiment, the second temperature is any temperature such that the asphalt brick devices 2 may be removed from the mold frames 22 without significant breakage and/or may be handled without risk of breakage.

At a step 50, the one or more asphalt brick devices 2 are removed from the one or more mold frames 22 of mold 20. In one embodiment, the lid 26 of mold 20 is first removed, and the mold 20 is inverted such that the asphalt brick devices 2 fall out of the mold 20 by gravity. For example, lid 24 is removed and mold 20 is inverted so that the asphalt brick devices 2 fall by gravity out of mold 200. In another embodiment, one or more interior walls of the mold frames 22 vibrate to urge the separation of the asphalt brick devices 2 from the mold frames 22. In embodiments of the asphalt brick devices 2 which are stackable, the asphalt brick devices 2 may be stacked, for example, on pallets to be transported or stored. At the completion of step 50, the asphalt brick devices 2 are ready for use. The method then proceeds to step 52 where the method ends.

In one preferred embodiment, the finished asphalt brick devices 2 are of a relative proportion, by weight or by volume, of aggregate to binding material to within one (1) percentage point of specification. For example, if a user selected a finished asphalt brick device 2 of 95.5% aggregate and 4.5% binding material, the finished asphalt brick device 2 will be between 94.5-96.5% and the binding material between 3.5-5.5%. This is an “aggregate/binder tolerance” of 1%. In a more preferred embodiment, the aggregate/binder tolerance is 0.5%. In a more preferred embodiment, the aggregate/binder tolerance is 0.1%.

In one preferred embodiment, the variability between finished asphalt brick devices 2 with respect to relative proportion, by weight or by volume, of aggregate to binding material is within one (1) percentage point. For example, for a particular batch of finished asphalt brick devices 2, all will have between 95-96% aggregate and between 4-5% binding material. This is a “batch tolerance” of 1%. In a more preferred embodiment, the batch tolerance is 0.5%. In a more preferred embodiment, the batch tolerance is 0.1%.

In one embodiment, a controller controls one or more aspects of the heating, mixing, cooling, and removal of the asphalt brick devices 2 while engaged in or with the mold 20. For example, a controller may control the temperature profile for the heating, to include the rate of temperature increase, the maximum temperature reached and length such a temperature is maintained, and the rate of decrease of the heating. Furthermore, the controller may control the mixing apparatus used to mix the asphalt brick devices 2, to include, for example, the RPM of the mixing and the duration of the mixing. A controller may also control the cooling parameters, such as duration and temperature of the cooling. Finally, the controller may control micro-vibration of one of more interior walls of the mold frames 22 so as to urge the separation of the asphalt brick devices 2 from the interior walls of the mold frames 22. In one embodiment, the controller utilizes control algorithms comprising at least one of on/off control, proportional control, differential control, integral control, state estimation, adaptive control and stochastic signal processing.

The overall use of asphalt brick devices 2 to perform an asphalt repair may be better understood in reference to the following illustrative example, which should not be construed as limiting the functional and operational characteristics of asphalt brick devices 2.

An embodiment of a method 60 for repairing an asphalt site using asphalt brick devices 2 is shown in FIG. 4. A general order for the steps of the method 60 is shown in FIG. 4. Generally, the method 60 starts with a start operation 62 and ends with an end operation 78. The method 60 can include more or fewer steps or can be arranged in a different sequence than those shown in FIG. 4. Some steps of the method 60 can be executed as a set of computer-executable instructions executed by a computer system and encoded or stored on a computer readable medium.

In step 64, the repair site requirements are determined. The repair site requirements are based on many parameters of the particular characteristics of the repair site, such as the humidity and temperature of the site, the exposure of the site to weather extremes or gradients, the age and composition of the existing asphalt, the work crew involved and repair capabilities available, cost, time, type of repair for example a roadway or a parking lot, and volume/extent of repairs. Generally, the requirements for resurfacing a section of roadway on an interstate highway subject to extreme temperature cycles would typically require an asphalt mix of relatively fine aggregate. In contrast, the requirements for patching several potholes in a city parking lot exposed to only moderate temperature cycles would typically require an asphalt mix of relatively larger, and less expensive, aggregate. As an example, in a scenario requiring the repair of seven moderately-sized potholes in a parking lot, it might be determined that 1 cubic yard of bulk asphalt mix is required of Type 4 mixture (per Table 1), with aggregate at 94% and binding material at 6%. This parking lot pothole scenario will be continued through the description of the steps of method 60 for illustrative proposes.

In step 66, the requirements for one or more types of asphalt brick devices 2 is determined. Here, the requirements for executing the repair are translated into a specific set of requirements for asphalt brick devices 2. For example, continuing the above parking lot scenario, the requirement for 1 cubic yard of bulk asphalt mix of Type 4 mixture with aggregate at 94% and binding material at 6% is translated into an order for asphalt brick devices 2. Assuming asphalt brick devices 2 of the “brick” embodiment described above (of rectangular shape of dimension 12×8×4 inch and thus of 0.22 ft³ volume), a total of 27 ft³/0.22 ft³=121.5 brick-type asphalt brick devices 2 are required. In one embodiment, such calculations may be implemented on a computer and/or be automated.

In step 68, an order is placed for the one or more types of asphalt brick devices 2. The order may be placed by any means of communication, to include by telephone, by cellular phone, text messaging, smart phones such as an iPhone and other forms of wireless communications. In the above parking lot pothole example, an order for 122 brick-type asphalt brick devices 2 of Type 4 mixture with aggregate at 94% and binding material at 6% would be placed. In one embodiment, such communications may be implemented on a computer and/or be automated and may be integrated with the calculations of step 66.

In step 70, the one or more types of asphalt brick devices 2 are manufactured. The process for manufacturing may be the process of FIG. 3. In the above parking lot pothole example, the 122 brick-type asphalt brick devices 2 of Type 4 mixture with aggregate at 94% and binding material at 6% would be manufactured.

In step 72, the finished one or more types of asphalt brick devices 2 are transported to the asphalt repair job site. Generally, a bulk quantity (by weight or by volume) of asphalt comprising multiple asphalt brick devices 2 can be easily determined by counting the number of unit-sized asphalt brick devices. Namely, in any surface repair or construction project, the number of unit-sized asphalt brick devices 2 can be easily counted and therefore the precise quantity of asphalt used in the project can be accounted for. Continuing the parking lot pothole example, 122 brick-type asphalt brick devices 2 of Type 4 mixture with aggregate at 94% and binding material at 6% would be transported to the parking lot repair job site.

In step 74, the one or more types of asphalt brick devices 2 are heated to the placing temperature (e.g., 250-325° F.) for use as a paving repair substance and positioned at the repair site. With respect to the parking lot pothole example, a subset of the 122 bricks are heated appropriately to form a hot asphalt concrete repair substance and portioned near each of the seven potholes in need of repair.

In step 76, the one or more types of asphalt brick devices 2, as heated and positioned at the repair site per step 74, are used to repair the asphalt roadway. With respect to the parking lot pothole example, a subset of the 122 bricks are used to repair the pothole. The method 60 then ends at step 78.

In one embodiment, one or more additives are added to one or more asphalt brick devices 2 on-site. Such additives may be specialized to the on-site repair conditions or allow dynamic, on-site additional tuning of the asphalt brick device 2 composition. For example, an additional sealant may be added to one or more asphalt brick devices 2 after heating and prior to use for road repair.

In one embodiment, the heating portion of step 74 is performed by an infrared heater, such as that disclosed in U.S. patent application Ser. No. 12/651,358 and U.S. patent application Ser. No. 13/167,888. In one embodiment, the heating portion of step 74 is performed by any means known to those skilled in the art, to include microwave heating and conductive heating and by energy sources known to those skilled in the art, to include propane.

Communications means and protocols may include any known to those skilled in the art, to include cellular telephony, internet and other data network means such as satellite communications and local area networks. As examples, the cellular telephony can comprise a GSM, CDMA, FDMA and/or analog cellular telephony transceiver capable of supporting voice, multimedia and/or data transfers over a cellular network. Alternatively or in addition, other wireless communications means may comprise a Wi-Fi, BLUETOOTH™, WiMax, infrared, or other wireless communications link. Cellular telephony and the other wireless communications can each be associated with a shared or a dedicated antenna. Data input/output and associated ports may be included to support communications over wired networks or links, for example with other communication devices, server devices, and/or peripheral devices. Examples of input/output means include an Ethernet port, a Universal Serial Bus (USB) port, Institute of Electrical and Electronics Engineers (IEEE) 1394, or other interface. Communications between various components can be carried by one or more buses.

Computer processing may include any known to those skilled in the art, to include desktop personal computers, laptops, mainframe computers, mobile devices and other computational devices.

Claims

1. An asphalt brick device having a predetermined shape, comprising:

a body having an upper surface, a lower surface, a front surface and a rear surface to define a specific shape;

wherein the body comprises an aggregate and a binding agent of a user-selected relative proportion by one of volume and of weight based on pre-determined calculations;

wherein the aggregate and binding agent are mixable when the body is in a first state;

wherein when the asphalt brick device is adapted to be transportable and stacked.

2. The device of claim 1, wherein the body is configured to operate in a first state and a second state, the first state a moldable state and the second state a solid state.

3. The device of claim 2, wherein the first state operates above a first temperature and the second state operates below a second temperature.

4. The device of claim 3, wherein the first temperature is 250 degree F.

5. The device of claim 1, wherein the aggregate is comprised of at least one of crushed stone, gravel, sand, silt and clay.

6. The device of claim 1, wherein the binding agent is comprised of a bituminous material.

7. The device of claim 1, wherein the binding agent is in the range of 4-8 percent by weight of the mixed aggregate and binding agent.

8. The device of claim 1, wherein the specific shape is of substantially rectangular shape.

9. The device of claim 1, further comprising a textured surface on at least one of the upper surface and the lower surface.

10. The device of claim 1, further comprising at least one protrusion on at least one of the upper surface and the lower surface and at least one conforming void on the opposite of the at least one of the upper surface and the lower surface.

11. The device of claim 10, wherein the protrusion and conforming void enable stacking of the asphalt brick device upon another asphalt brick device.

12. The device of claim 10, wherein the conforming void is on the lower surface and is configured to engage tines of a forklift.

13. The device of claim 1, further comprising a scored portion on at least one of the upper surface and the lower surface, the scored portion enabling a substantially controlled breaking of the body into two pieces substantially along an axis aligned with the scored portion.

14. The device of claim 1, wherein the asphalt brick device weighs no more than 40 lbs.

15. The device of claim 8, wherein the substantially rectangular shape is of approximate dimension 12 inches by 8 inches by 4 inches.

16. The device of claim 1, further comprising a nanoparticle sensor.

17. The device of claim 1, wherein the body is a plurality of bodies wrapped to facilitate transport by a user.

18. A method for manufacturing a portable asphalt brick device having a predetermined shape and consistency, comprising:

receiving a quantity of aggregate and a quantity of binding agent based on a pre-determined location of ultimate use;

heating the quantity of aggregate and the quantity of binding agent to a first temperature to form an asphalt mix;

mixing the asphalt mix to obtain a substantially uniform composition;

compressing the asphalt mix into a mold;

forming at least one portable asphalt brick device in the mold;

cooling the at least one portable asphalt brick device below a second temperature.

19. The method of claim 18, wherein the first temperature is 250 degree F.

20. The method of claim 18, wherein the mold is configured to form a plurality of the portable asphalt brick devices comprising at least one protrusion on an upper surface and at least one conforming void on a lower surface of each portable asphalt brick device, the protrusion and conforming void enabling stacking of the asphalt brick device upon another asphalt brick device.

21. The method of claim 20, wherein the mold is configured to form at least one scored portion on the upper surface of each asphalt brick device, the scored portion enabling a substantially controlled breaking of the asphalt brick device into at least two pieces substantially along an axis aligned with the scored portion.

22. The method of claim 18, wherein the at least one portable asphalt brick device comprise a nanoparticle sensor.

23. The method of claim 18, wherein the at least one portable asphalt brick device is a plurality of portable asphalt brick devices wrapped to facilitate transport by a user.

24. A method of using a preformed portable asphalt brick device to repair a road deformity, comprising:

determining the composition of the preformed portable asphalt brick device based on a geographic location of the road deformity;

ordering the preformed portable asphalt brick device;

manufacturing the asphalt brick device by mixing at least an aggregate material and a binding agent;

forming a shape of the preformed portable asphalt brick device;

transporting the preformed portable asphalt brick device to the repair site;

heating the preformed portable asphalt brick device to form a paving repair substance; and

repairing the repair site using the paving repair substance.

25. The method of claim 24, wherein the composition of the preformed portable asphalt brick device is based at least upon the temperature and use properties of the geographic location of the road deformity.

26. The method of claim 24, further comprising adding an additive to the paving repair substance.