WO2022035921A1

WO2022035921A1 - Layered materials such as roadway

Info

Publication number: WO2022035921A1
Application number: PCT/US2021/045472
Authority: WO
Inventors: Marvin Keller Exline; Andrew Jacob EICHER; Todd Thomas; Joseph Lorenc
Original assignee: Asphalt Materials, Inc.
Priority date: 2020-08-11
Filing date: 2021-08-11
Publication date: 2022-02-17

Abstract

Methods for adhering secondary bituminous hinder layers to underlying substrates using vinyl polymer.

Description

LAYERED MATERIALS COMPRISING VINYL POLYMER

ADHESION PROMOTERS AND DETACKIFIERS

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Patent Application number 63/064,175 filed on August 11, 2020, which is hereby incorporated herein by reference in its entirety.

BACKGROUND

Layered materials such as roadways, parking lots and runways may include several layers of bituminous or non-bituminous materials. Often times, roadways may include a first (original) asphalt or cement concrete layer. Over time, this first layer of material requires resurfacing, such that subsequent pavement layers are applied over the substrate. In some cases, the substrate surface is “milled” to remove imperfections such as rutting and/or cracking. In an effort to farther aid the adhesion of new pavement layers over the substrate, intermediate bituminous materials including “tack coat" and/or “longitudinal joint sealant” layers may be applied on the substrate surface to act as a “glue” for the new asphalt applied above. Nonetheless, in some cases, difficulties in getting these intervening bituminous layers to adhere to the substrate surface may be observed, particularly in cases where the substrate surface is milled and/or includes dirt, dust, or other aggregate-type particle “fines” that can inhibit adhesion of these intervening bituminous layers. Moreover, in some cases the surface of the bituminous layer itself may be tacky, causing sticking to construction equipment and tires that pass over it prior to the application of an overlying pavement layer. Accordingly, there remains a need to effectively adhere secondary bituminous layers to their underlying substrate layers, while keeping the surface of those secondary bituminous layers non-tacky. SUMMARY

The present disclosure relates to layered materials comprising: a first substrate layer; a second layer of bituminous material; and a vinyl polymer adhesion promoter positioned between the first and second layers. In some embodiments, the layered material comprises a roadway. In some embodiments, the vinyl polymer adhesion promoter enhances adhesion of the second layer of bituminous material to the first substrate layer. In some embodiments, the layered material comprises a layer of bituminous material having a surface; and a layer of a detackifier on the surface of the bituminous material layer. In certain embodiments, the detackifier comprises a vinyl polymer.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the present disclosure, reference will now be made to certain embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the disclosure is thereby intended, such alterations and further modifications, and such further applications of the principles of the disclosure as described herein being contemplated as would normally occur to one skilled in the art to which the disclosure relates. Additionally, in the detailed description below, numerous alternatives are given for various features. It will be understood that each such disclosed alternative, or combinations of such alternatives, can be combined with the more generalized features discussed in the Summary above, or set forth in the embodiments described below to provide additional disclosed embodiments herein.

In some embodiments, the present disclosure relates to methods for preparing a roadway, parking lot or runway structure. In certain embodiments, the method comprises: identifying a first substrate layer having a surface; disposing an adhesion promoter comprising a vinyl polymer upon the surface of the first layer; and applying a second layer of bituminous material over the first layer. In certain embodiments, it has been surprisingly discovered that vinyl polymers can aid in the adhesion of the second layer to the first layer. Exemplary vinyl polymers include, but are not limited to, polyvinyl alcohol and polyvinyl acetate. In certain embodiments, the vinyl polymer may be modified with one or more vinyl polymer modifiers, such as boric acid.

In some embodiments, the first substrate layer may comprise an old (original) cement concrete or asphalt concrete, while the second layer of material comprises a bituminous binder material. In certain embodiments, the first substrate layer may have a surface covered with particles or dust (aka, “fines”), which may result from the processing (e.g., milling) of the substrate. These fines, in turn, can prevent proper adhesion of a secondary bituminous binder material that is disposed on top of the substrate.

In some embodiments, the secondary bituminous layer may comprise a tack coat (e.g., a hot tack layer or non-tracking tack coat emulsion) that serves as a binder between the first substrate and a future third layer of material such as a new asphalt surface (eg-, a hot mix asphalt). In some embodiments, the second bituminous binder layer may comprise a longitudinal joint sealant, which may be placed in a band of about 4 to about 24 inches on the substrate at the future location of a longitudinal joint formed by the placement of two asphalt mats over the sealant. In some embodiments, the second bituminous layer is placed down on the substrate and may lay exposed to construction equipment and vehicle traffic prior to the placement of a third overlying layer. Therefore, in some cases, the second bituminous layer may be “pulled” off of the underlying substrate from equipment tracks or vehicle tires if it is not adhered properly to the substrate.

Thus, in certain embodiments, the methods described herein comprise the disposition of an adhesion promoter comprising a vinyl polymer to help adhere the second bituminous binder layer to the first substrate layer. Without being bound to any particular theory, in certain embodiments Applicant has found that vinyl polymer can penetrate the fines and “bite” into the substrate (e.g., milled surface) while bonding to the second bituminous layer, thereby increasing the adhesion of the bituminous binder to the substrate. It is believed, in certain embodiments, that the vinyl polymer aids in the immobilization of fines on the substrate, thereby permitting the overlying bituminous material to bond to the underlying substrate via the adhesion promoter. In certain embodiments, the adhesion promoter containing a vinyl polymer may comprise an aqueous composition. In certain embodiments, the vinyl polymer comprises about 0.1 to about 10 wt. % of the adhesion promoter composition, such as about 0.5 to about 5 wt. %, or about 1 to about 2 wt. %. In certain embodiments, the adhesion promoter is administered to the surface of the substrate by a distributor (e.g., manual or vehicle sprayer) at a rate of about 0.001 to about 0.20 gallons/yard², such as about 0.005 to about 0.15 or about 0.01 to about 0.10 gallons/yard². In certain embodiments, the adhesion promotor composition may further comprise one or more adhesion promoter additives, such as boric acid.

In certain embodiments, the second bituminous layer comprises an asphalt material, an elastomeric polymer, and a wax. In certain embodiments, the elastomeric polymer is selected from a styrene-butadiene- styrene polymer, an ethylene-styrene interpolymer, a styrene-butadiene rubber, and an ethylene terpolymer. In certain embodiments, the wax is selected from a vegetable wax, an animal wax, a coal wax, a petroleum wax, an amide wax, or a waxy fatty acid soap. In certain embodiments, the second bituminous layer comprises at least one of sulfur or a filler. Exemplary fillers include, but are not limited to, fumed silica and filmed alumina.

In some embodiments, the methods described herein comprise the preparation of a layered material comprising a bituminous layer of material, such as a tack coat or a longitudinal joint sealant. In some embodiments, the surface of such a bituminous layer may be tacky, which can lead to adherence to vehicle tires and construction equipment prior to placement of a new pavement layer. Accordingly, in certain embodiments the layered material comprises a layer of bituminous material having a surface; and a layer of a detackifier positioned on the surface of the bituminous material. In certain embodiments, the detackifier comprises a vinyl polymer. In certain embodiments, the vinyl polymer is selected from polyvinyl alcohol and polyvinyl acetate. In certain embodiments, the vinyl polymer may be modified with one or more vinyl polymer modifiers, such as boric acid. In some embodiments, vinyl polymer is included into the bituminous layer of material (e.g., the second layer of bituminous material). For example, in some embodiments the bituminous layer of material may comprise a hot tack material or aqueous emulsion of non-tracking tack material. Without being bound to any particular theory, in certain embodiments the vinyl polymer is added to the non- tracking tack material composition and becomes a component of the emulsion. In some embodiments, when used in an asphalt-based emulsion, the vinyl polymer (e.g., polyvinyl alcohol and/or polyvinyl acetate) will separate or accumulate at the surface of the emulsion, thereby creating a “detackifier” at the surface of the resulting cured or uncured asphalt emulsion film. Therefore, in certain embodiments the non-tracking tack material comprises: an asphalt material, an emulsifier (e.g., anionic), a stabilizer (e.g., a vinyl polymer, and optionally a dispersant). In certain embodiments the non-tracking tack material provided for application on a roadway as an emulsion, wherein the emulsion comprises water, an asphalt material, an emulsifier, a stabilizer, and optionally a dispersant.

The uses of the terms "a" and "an" and "the" and similar references in the context of describing the disclosure (especially in the context of the following claims) are to be construed to cover both the singular and the plural unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

While the present disclosure has been illustrated and described in detail in the drawings and the foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. In addition, all references cited herein are indicative of the level of skill in the art and are hereby incorporated by reference in their entirety.

EMBODIMENTS

The following provides an enumerated listing of some of the embodiments disclosed herein. It will be understood that this listing is non-limiting, and that individual features or combinations of features (e.g., 2, 3 or 4 features) as described in the Detailed Description above can be incorporated with the below -listed Embodiments to provide additional disclosed embodiments herein.

1. A layered material comprising: a first substrate layer; a second layer of bituminous material; and a vinyl polymer material positioned between the first and second layers.

2. The layered material of claim 1, wherein the second layer of bituminous material is positioned over the first substrate layer.

3. The layered material of any one of embodiments 1 to 2, wherein the vinyl polymer material enhances adhesion of the second layer of bituminous material to the first substrate layer.

4. The layered material of embodiments 1 to 3, wherein the layered material comprises a roadway.

5. The layered material of embodiments 1 to 4, wherein the first substrate layer comprises a pavement having a surface.

6. The layered material of embodiment 5, wherein the pavement comprises a milled surface. 7. The layered material of any one of embodiments 1 to 6, wherein the second layer of bituminous material comprises a bituminous binder.

8. The layered material of embodiment 7, wherein the bituminous binder comprises a tack coat or a longitudinal joint sealant.

9. The layered material of any one of embodiments 7 to 8, wherein the bituminous binder comprises an asphalt material, an elastomeric polymer, and a wax.

10. The layered material of embodiment 9, wherein the bituminous binder further comprises at least one component selected from sulfur or a filler.

11. The layered material of embodiment 10, wherein the filler comprises fumed silica.

12. The layered material of any one of embodiments 1 to 11, further comprising a third layer of bituminous material.

13. The layered material of embodiment 12, wherein the third layer is positioned over the second layer.

14. The layered material of embodiment 13, wherein the third layer comprises an asphalt pavement layer.

15. A method of adhering bituminous materials, comprising: identifying a first substrate layer having a surface; disposing an adhesion promoter comprising a vinyl polymer upon the surface of the first layer; and applying a second layer of bituminous material over the first layer.

16. The method of embodiment 15, wherein the vinyl polymer aids in the adhesion, of the second layer to the first layer.

17. The method of any one of embodiments 15-16, wherein the adhesion promoter comprises an aqueous composition.

18. The method according to embodiment 17, wherein the adhesion promoter is disposed at a rate of about 0.01 to about 0.20 gallons/yard².

19. The method of any one of embodiments 15-18, wherein the adhesion promoter comprises about 1 to about 2 wt. % of a vinyl polymer. 20. The layered material of embodiment 14, wherein the asphalt pavement layer comprises a hot mix asphalt.

21. The layered material according to any one of embodiments 1-14, wherein the vinyl polymer is selected from polyvinyl alcohol and polyvinyl acetate.

22. The layered material according to any one of embodiments 1-14, wherein the vinyl polymer comprises a polyvinyl alcohol.

23. The method according to any one of embodiments 14-19, wherein the vinyl polymer is selected from polyvinyl alcohol and polyvinyl acetate.

24. The method according to any one of embodiments 14-19, wherein the vinyl polymer comprises a polyvinyl alcohol.

25. The layered material according to any one of embodiments 1-14, further comprising a detackifier positioned on the surface of the second bituminous layer.

26. The layered material of embodiment 25, wherein the detackifier comprises a vinyl polymer.

27. The layered material of embodiment 26, wherein the detackifier is selected from polyvinyl alcohol and polyvinyl acetate.

28. A layered material comprising a bituminous material layer having a surface, and a detackifier positioned on the surface of the bituminous material.

29. The layered material of embodiment 28, wherein the detackifier comprises a vinyl polymer.

30. A method of preparing a layered material, comprising: identifying a substrate having a surface, wherein fines cover at least a portion of the surface of the substrate: immobilizing the fines on the surface of the substrate by contacting the fines and the surface with an adhesion promoter; and positioning a layer of bituminous material over the surface of the substrate and immobilized fines.

31. The method of embodiment 30, wherein the substrate comprises a milled cement concrete or milled asphalt concrete. 32. The method according to any one of embodiments 30-31, wherein the fines comprise dirt, dust, or aggregate particles.

33. The method according to any one of embodiments 30-32, wherein the bituminous material layer comprises a tack coat or a longitudinal joint sealant.

34. An non-tracking tack coat comprising: an asphalt; an emulsifier; a stabilizer; and a vinyl polymer.

35. An asphalt-based emulsion comprising: water; an asphalt; an emulsifier; a stabilizer; and a vinyl polymer.

36. The layered material of any one of embodiments 1-14, wherein the vinyl polymer material is modified with boric acid.

Claims

CLAIMS What is claimed is:

3. The layered material of any one of claims 1 to 2, wherein the vinyl polymer material enhances adhesion of the second layer of bituminous material to the first substrate layer.

4. The layered material of claims 1 to 3, wherein the layered material comprises a roadway.

5. The layered material of claims 1 to 4, wherein the first substrate layer comprises a pavement having a surface.

6. The layered material of claim 5, wherein the pavement comprises a milled surface.

7. The layered material of any one of claims 1 to 6, wherein the second layer of bituminous material comprises a bituminous binder.

8. The layered material of claim 7, wherein the bituminous binder comprises a tack coat or a longitudinal joint sealant.

9. The layered material of any one of claims 7 to 8, wherein the bituminous binder comprises an asphalt material, an elastomeric polymer, and a wax.

10. The layered material of claim 9, wherein the bituminous binder farther comprises at least one component selected from sulfur or a filler.

11. The layered material of claim 10, wherein the filler comprises famed silica.

12. The layered material of any one of claims 1 to 11, further comprising a third layer of bituminous material.

13. The layered material of claim 12, wherein the third layer is positioned over the second layer.

14. The layered material of claim 13, wherein the third layer comprises an asphalt pavement layer.

16. The method of claim 15, wherein the vinyl polymer aids in the adhesion, of the second layer to the first layer.

17. The method of any of claims 15-16, wherein the adhesion promoter comprises an aqueous composition.

18. The method according to claim 17, wherein the adhesion promoter is disposed at a rate of about 0.01 to about 0.20 gallons/yard².

19. The method of any one of claims 15-18, wherein the adhesion promoter comprises about 1 to about 2 wt. % of a vinyl polymer.

20. The layered material of claim 14, wherein the asphalt pavement layer comprises a hot mix asphalt.

21. The layered material according to any one of claims 1-14, wherein the vinyl polymer is selected from polyvinyl alcohol and polyvinyl acetate.

22. The layered material according to any one of claims 1-14, wherein the vinyl polymer comprises a polyvinyl alcohol.

23. The method according to any one of claims 14-19, wherein the vinyl polymer is selected from polyvinyl alcohol and polyvinyl acetate.

24. The method according to any one of claims 14-19, wherein the vinyl polymer comprises a polyvinyl alcohol.

25. The layered material according to any one of claims 1-14, further comprising a detackifier positioned on the surface of the second bituminous layer.

26. The layered material of claim 25, wherein the detackifier comprises a vinyl polymer.

27. The layered material of claim 26, wherein the detackifier is selected from polyvinyl alcohol and polyvinyl acetate.

29. The layered material of claim 28, wherein the detackifier comprises a vinyl polymer.

31. The method of claim 30, wherein the substrate comprises a milled cement concrete or milled asphalt concrete.

32. The method according to any one of claims 30-31, wherein the fines comprise dirt, dust, or aggregate particles.

33. The method according to any one of claims 30-32, wherein the bituminous material layer comprises a tack coat or a longitudinal joint sealant.

36. The layered material of any one of claims 1-14, wherein the vinyl polymer material is modified with boric acid.