GB2481669A

GB2481669A - Pothole repair

Info

Publication number: GB2481669A
Application number: GB201105223A
Authority: GB
Inventors: Matthew Richard Dean Lobley; David Boothroyd
Original assignee: ROAD AHEAD UK Ltd
Current assignee: ROAD AHEAD UK Ltd
Priority date: 2010-03-29
Filing date: 2011-03-28
Publication date: 2012-01-04
Anticipated expiration: 2031-03-28
Also published as: GB201005265D0; GB2481669B; GB201105223D0

Abstract

Apparatus for repairing a road surface defect, eg pothole, with at least one pre-formed block, comprises rotary cutter means 2,3 and rotary cutter moving means which may be hydraulic, pneumatic or electric. In use, the rotary cutter means is moved along a pre-determined path so as to mill the road surface defect into a recess suitable for receiving the block(s). The cutting apparatus may be a milling machine with rotary cutters mounted on driven vertical spindle(s) 2. A variety of shapes may be milled, eg having lugs, eg in the shape of a jigsaw puzzle, to provide mechanical keying and enabling blocks to be linked to fill a larger recess. The block may be moulded under pressure and may remain in the mould until ready to drop into a recess. The material of the block may be the same as the original road surface or may be of compound material eg recycled planings, power station ash or tyre crumb. The block may contain an electronic ID chip readable by a hand-held scanner to enable a record of the repair. The apparatus may also be used for manholes, drains and road fitments.

Description

POTHOLE REPAIR

Potholes or localised road surface damage, are a serious problem throughout most of the world. Conventional methods of repair are either very temporary or require an expensive and labour intensive crew. In addition conventional methods of permanent repair require substantial quantities of tarmac to be stored at high temperatures for protracted periods with the ensuing cost and environmental damage. Such repairs can only be carried out effectively during fine weather conditions. It is against this background that the present invention has been made.

According to the present invention there is provided an apparatus for repairing a road surface defect as defined in the appended claim 1.

A second aspect of the present invention provides a block as recited in the appended independent claim 25.

A third aspect of the present invention provides a method of repairing a road surface defect as recited in the appended independent claim 36.

Further preferable features of the present invention are provided as recited in the appended dependent claims.

The pothole repair system can be used in all weather conditions. No heating is required either during storage, transportation or carrying out the repair. Blocks with a female lug enable the linking of more than one block to fill a larger recessed hole.

An example of the invention will now be described by referring to the accompanying drawings: * Figure 1 (top illustration on sheet) shows a milling machine with contra-rotating milling heads; and * Figure 2 (bottom illustration on sheet) shows a block for placement in the milled hole according to the invention with the rotation path of the mechanism overlaid A description of the features referred to in figures 1 and 2 is shown below: 1. Linear and circular motion mechanism 2. Cutting tool spindles 3. Contra rotating milling cutters 4. Milled recess in road 5. Plan showing recess and block 6. Rotation path of mechanism The system comprises a milling assembly (figure 1). Using CNC technology (Computer Numerical Control) the milling cutter machines a recess in the road surface encompassing the damaged section and into the undamaged area 4. The recess is in the shape of a jigsaw puzzle piece or similar to increase the area of contact and to provide a mechanical key 5.

On completion of the machining a sealant emulsion is sprayed to seal the existing road surface and to provide a bond. A block of pre-formed material is then dropped into the recess. The recess is machined accurately and is parallel to the road surface to provide a repair which is flush to the existing road surface. Once the block has been positioned the road is ready for immediate use.

The present invention is a method and apparatus for the repair of potholes in asphalt/tarmac road surfaces. It is designed for but not restricted to carrying out efficient repairs to road surfaces. The method comprises two main elements.

The first element is a milling machine (figure 1) which can machine a recess from the road surface. The second element is a repair block, pre-formed to match the shape of the recess 5.

The milling machine (figure 1) is designed to fit to a road vehicle of the type normally used by road repair contractors. In another embodiment the milling machine can be trailer mounted or free standing. In another embodiment the milling machine can be attached to the operating arm of a piece of mechanical plant such as an excavator. In a further embodiment the drilling rig forms part of a modified tail lift attached to the rear of the vehicle. The tail lift modification is such that it provides a milling platform in addition to a device for placing the block in position over the milled recess.

The milling machine comprises vertical spindle(s) 2 mounted rotary cutter controlled by software or manually moved around a template or pantograph to produce an accurate recess in the road surface. The recess can be the shape of a jigsaw puzzle piece in order to provide mechanical keys and the maximum contact area.

In one embodiment of the machine two opposite handed cutters 2 are used which contra-rotate 1 to reduce the amount of torque transmitted to the securing mechanism. The vertical spindles move in opposite directions in order to reduce the journal loads transmitted to the securing mechanism.

The rotary cutter(s) 3 are either diamond impregnated or tungsten carbide tipped but the use of other materials is not precluded. In one embodiment, the initial entry angle of milling head will be both vertical and horizontal until the milling head reaches its required depth.

During positioning and milling the rotating parts are protected by a guard which may or may not form part of the supporting mechanism. Integral suction ports connected to a vacuum system provide collection of dust and small cuttings.

Provision is made for the introduction of a cooling medium which can be water based or a suitable emulsifring product which can be delivered as a stream or in aerosol form.

The milling machine comprises actuators and linear/radial guides to allow accurate control.

The invention is designed for one man operation although in certain countries it may be necessary for a banksman to be in attendance in order to comply with Health and Safety regulations.

The apparatus according to the invention is powered by hydraulic motors and actuators but in other embodiments can be powered by pneumatic or electric power. Hydraulic motors and actuators can be powered either by the PTO shaft hydraulic pump normally fitted to contractors vehicles or by an independent portable hydraulic power pack. A range of software in the CNC system can permit the milling of a variety of shapes enabling the milling machine to be capable of making recesses for purposes other than road repair for example

S

man holes, drains, road fitments etc. The system will also enable more than one bloc to be located side by side to enable areas with multiple potholes to be repaired.

The benefits of the jigsaw shape include: * Increased peripheral contact * Precise mechanical location in the x and y axis * No sharp corners in the existing road surface where stresses could be concentrated Machining the recess provides: * Accurate fit * Level surface of repair * Even stress absorption of repair The block is pre-formed and stored ready for use.

In one embodiment of the block it is manufactured using a similar tarmac formulation to that used in the original road surface. The fluid tarmac is introduced into a unique design of mould. The tarmac is then compressed using an hydraulic press with a vibrating plate to form a block which will fit accurately into the recess formed by the milling machine.

In one embodiment of the block reinforcing agents are added to support the block during handling and transportation.

In another embodiment the block remains in the mould for transportation and handling. A suction device holds the block in the mould whilst the mould is * 6 inverted prior to fitting in the recess. When the block is in position the vacuum is released and light air pressure applied to free the tarmac block and allow it to drop into the recess.

In another embodiment the block is constructed from a compound material which may include but is not limited to recycled tarmac planings, power station ash, tyre crumb. The block construction will match the existing road surface in mechanical properties i.e. coefficient of friction, wear rate, compressive strength.

The repair block contains an electronic "chip" which can be read by a hand, held scanner or PDA. The information relating to the block serial number, the repair contractor, the precise time of the repair and its geographical location is sent via GPRS to a data base in order to provide a permanent record of the repair. This information can be integrated into a local authority highways department data base for record keeping, performance monitoring and contractor auditing. A version of the repair block has one or more female lugs to enable more than one block to be linked to fill a larger recess.

In one embodiment multiple blocks are stored and transported to a use location in a carousel, said carousel of the form of an open ended tube with blocks stacked within it. In use, the carousel is positioned over the milled recess such that the lowest block of said stack can be deposited into said recess. The carousel can then be repositioned in preparation for depositing a further block.

In one embodiment a recess can be filled with more than one block. In use a first block is located in said recess. A male andlor female member is then milled in said block so a further block can engage therein by means of a corresponding male and/or female member. Said male and/or female members of each block may dovetail with each other. Alternatively said blocks may overlap each other to form a shape comparable with a Venn-diagram.

The system and apparatus provided by the two components of the invention provide an effective permanent pothole repair solution which can be used all year round in any weather at considerably less cost and damage to the environment of current methods.

Claims

CLAIMS: 1. An apparatus for repairing a road surface defect with at least one block, the apparatus comprising: rotary cutter means, and rotary cutter moving means, wherein, in use, said rotary cutter moving means directs said rotary cutter means through a pre-determined path so as to mill said road surface defect into a recess suitable for receiving said at least one block.
2. An apparatus according to claim 1, wherein the rotary cutter means comprises a contra-rotating milling head.
3. An apparatus according to claim 1 or 2, wherein the rotary cutter means comprises a first and second rotary cutter.
4. An apparatus according to claim 3, wherein the first rotary cutter is opposite-handed to the second rotary cutter.
5. An apparatus according to any of the preceding claims, wherein the rotary cutter moving means controls the position of the rotary cutter means in the x-axis, y-axis and z-axis with respect to the road surface defect.
6. An apparatus according to any of the preceding claims, wherein the angle of the rotary cutter means with respect to the road surface defect is varied by the rotary cutter moving means.
7. An apparatus according to any of the preceding claims, wherein the pre-determined path is defined by a programmed sequence of motions.
8. An apparatus according to any of the preceding claims, wherein the pre-determined path is such that, in use, the rotary cutter means mills a recess shaped so as to dovetail with said at least one block received therein.
9. An apparatus according to any of the preceding claims, wherein the pre-determined path is such that, in use, the rotary cutter means mills a recess shaped so as to receive a plurality of blocks.
10. An apparatus according to any of the preceding claims, wherein the pre-determined path is such that, in use, the rotary cutter means mills a recess comprising a base parallel to the road surface.
11. An apparatus according to any of the preceding claims, further comprising guard means positioned, in use, so as to protect the user from debris and the rotary cutter means.
12. An apparatus according to any of the preceding claims, further comprising suction means for debris removal.
13. An apparatus according to any of the preceding claims, further comprising cooling means for reducing the operating temperature of the rotary cutter means.
14. An apparatus according to claim 13, wherein the cooling means is water based.
15. An apparatus according to claim 13 or 14, wherein the cooling means is delivered in liquid form.
16. An apparatus according to claim 13 or 14, wherein the cooling means is delivered in aerosol form.
17. An apparatus according to any of the preceding claims, wherein said apparatus is free-standing.
18. An apparatus according to any of the preceding claims, further comprising mounting means for mounting said apparatus to a vehicle, trailer, excavator operating arm or tail lift of the type commonly used in the art of road repair.
19. An apparatus according to any of the preceding claims, wherein the rotary cutter is diamond impregnated.
20. An apparatus according to any of claims 1 to 18, wherein the rotary cutter is tungsten carbide tipped.
21. An apparatus according to any of the preceding claims powered by a PTO shaft hydraulic pump commonly present on vehicles used in the art of road repair.
22. An apparatus according to any of claims 1 to 20 powered by means of direct or indirect drive from an engine.
23. An apparatus according to any of the preceding claims, wherein the road surface material is tarmac.
24. An apparatus according to any of the preceding claims, further comprising means for transporting a plurality of blocks in a stack to a use location, wherein, in use, said means is positioned over the milled recess such that the lowest block of said stack can be deposited into said recess.
25. A block for use with an apparatus according to the invention, wherein said block is preformed from a mould prior to said use.
26. A block according to claim 25, wherein said block is shaped so as to locate in the recess formed by the rotary cutter means.
27. A block according to claim 25 or 26, further comprising male and/or female receiving means.
28. A block according to claim 27, wherein the male and/or female receiving means are dovetail means.
29. A block according to any of claims 25 to 28, further comprising identification means, wherein said identification means includes information relating to one or niore of block serial number, repair contractor, time of use and/or location.
30. A block according to claim 29, wherein the identification means is read by a hand-held scanner.
31. A block according to claim 29 or 30, wherein the identification means comprises a barcode.
32. A block according to claim 29 or 30, wherein the identification means comprises an RFID tag.
33. A block according to any of claims 25 to 32, wherein the block is made of a compound material which may include one or more of tarmac planings, power station ash andlor tyre crumb.
34. A block according to any of claims 25 to 33, further comprising reinforcing means to support said block during handling.
35. A block according to any of claims 25 to 34, wherein the mechanical properties of the block are substantially equal to the mechanical properties of a tarmac road surface.
36. A method of repairing a road surface defect, comprising the steps of: a) positioning rotary cutter means according to any of claims 1 to 24 in or adjacent to said road surface defect, b) milling said road surface defect into a recess suitable for receiving at least one block according to any of claims 25 to 35; and c) locating the at least one block according to any of claims 25 to 35 into said recess.
37. A method according to claim 36, further comprising the step of applying bonding sealant to the surface of the recess before performing step c).
38. A method according to claim 36 or 37, wherein step c) comprises locating a plurality of blocks into said recess.
39. A method according to claim 38, further comprising the step d) of milling the at least one block such that a further block may locate in said recess.
40. A method according to any of claims 36 to 39, wherein the at least one block remains in a mould prior to step c).
41. A method according to claim 40, wherein the block is held in said mould by suction means.
42. A method according to claim 41, further comprising the step of deactivating the suction means and applying air pressure such that the block is freed from said mould.
43. A method according to any of claims 36 to 42, wherein step c) is performed by suction means.
44. A method according to any of claims 36 to 42, wherein step c) is performed by a crane or lifting arm.
45. A method according to any of claims 36 to 44, wherein each step is performed by one operator.
46. An apparatus for repairing a road surface defect substantially as herein described with reference to the accompanying drawings.
47. A block for repairing a road surface defect substantially as herein described with reference to the accompanying drawings.
48. A method of repairing a road surface defect substantially as herein described with reference to the accompanying drawings.*::r: INTELLECTUAL . ... PROPERTY OFFICE Application No: GB 1105223.0 Examiner: John Twin Claims searched: ito 24; 36 to 45 Date of search: 2 August 2011 Patents Act 1977: Search Report under Section 17 Documents considered to be relevant: Category Relevant Identity of document and passage or figure of particular relevance to claims X 1,5,9,10,1 EP2213799A2 2,18,19,2 (Mainenti) -see eg figs.7-10; para.61 3,24,36 at least X 1,5,7,10,1 US 5333969 A 2,18,20-(Blaha et al.) -example of pavement milling machine for forming a 22 recess but without disclosure of the recess being filled by preformed block(s) X 1,36 US3915582A (Clarke) -see eg column 1, lines 30-45; percussive rather than rotary cutting heads Categories: X Document indicating lack of novelty or inventive A Document indicating technological background and/or state step of the art.Y Document indicating lack of inventive step if P Document published on or after the declared priority date but combined with one or more other documents of before the filing date of this invention.same category.& Member of the same patent family E Patent document published on or after, but with priority date earlier than, the filing date of this application.Field of Search:Search of GB, EP. WO & US patent documents classified in the following areas of the UKCX Worldwide search of patent documents classified in the following areas of the IPC EO1C The following online and other databases have been used in the preparation of this search report EPODOC, TXTE, WPI International Classification: Subclass Subgroup Valid From EO1C 0023/06 Oi/01/2006 EO1C 0011/00 01/01/2006 Intellectual Property Office is an operating name of the Patent Office www.ipo.gov.uk