Leveling plate assembly and method of manufacture

Abstract

A screed plate for a leveling assembly towed by a mobile paver is manufactured from a support plate and a plurality of geometrically textured bosses. The support plate includes a lower material contact surface that may be flat and planar. Each of the plurality of geometrically textured bosses includes a mounting base adapted for attachment to the support plate and a protruding body adapted to project relative to the lower material contact surface. The plurality of geometrically textured bosses may be arranged in a textured pattern to physically manipulate the paving material and may be attached to the support plate as a refurbishment kit.

Description

Technical Field

[0001] The patent disclosure generally relates to a mobile paver for performing paving operations, and more specifically, to a slab plate for attaching to a floating leveling assembly to distribute and compact paving material to produce a paving mat. Background Technology

[0002] Mobile pavers (also known as road pavers) are used during paving operations to apply, spread, and compact paving material onto a paving mat on the ground or subgrade to create a smooth, hard surface, such as roads, parking lots, or other paved areas, for cars, trucks, and other vehicles to travel on. Typical examples of paving materials used to create the paved surface are hot asphalt mixtures of hard aggregates (such as rock), finer materials (such as sand), and asphalt mixtures or binders, along with possible other additives and modifiers. The paving material is initially in a loose, almost fluid state to facilitate spreading and distributing it across the work surface and covering the desired area.

[0003] To distribute paving material, a mobile paver can be operatively associated with a floating screed assembly, which is attached to the paver and towed along the paver's direction of travel. The screed assembly includes one or more flat metal slabs attached to the underside of a screed frame. The mobile paver delivers paving material onto a working surface in front of the forward edge of the screed, which moves over the distributed material by the forward travel of the mobile paver. The floating screed assembly can be self-leveling and attached to the mobile paver to float freely over the distributed paving material, and the weight of the screed assembly and the flatness of the screed spread and compact the paving material to form a paving mat. In possible variations, the screed assembly can be configured to vibrate to improve the compaction of the paving material, and the screed can be heated to prevent paving material from adhering to it.

[0004] Typically, it is desirable to distribute paving material as uniformly and homogeneously as possible to produce a paving mat with sufficient density and smoothness for use as a road or similar paving surface that can withstand repeated vehicle traffic and varying climatic conditions. To improve the homogeneity and uniform distribution of aggregates and fine particles within an asphalt mixture, U.S. Patent 10,156,050 (“050 Patent”) describes a screed assembly with a textured surface on a slab. The textured surface may include corrugations arranged parallel or perpendicular to the travel direction of the mobile paver. The 050 Patent describes texturing on the underside of the slab as resulting in a more homogeneous classification and distribution of aggregates in the paving material, thereby producing a more durable paving surface. Summary of the Invention

[0005] In one aspect, this disclosure describes a slab for a screed assembly configured to be towed by a mobile paver. The slab may be assembled from support plates having a front edge and a rear edge. The support plates also have an upper attachment surface extending between the front and rear edges, and a lower material contact surface adapted to compact and compress paving material sliding beneath the slab. The slab assembly also has a plurality of geotextured bosses mountable to the support plates. Each of the plurality of geotextured bosses includes a mounting base adapted for placement adjacent to the support plate and a protruding body adapted to project from the lower material contact surface. To connect the plurality of geotextured bosses to the support plates, the slab also includes a plurality of structural joints.

[0006] In another aspect, this disclosure describes a method for assembling a flat plate from a support plate and a plurality of geometrically textured bosses. The method involves manufacturing a support plate having a front edge, a rear edge, an upper attachment surface, and a lower material contact surface opposite the upper attachment surface. The method also includes manufacturing a plurality of geometrically textured bosses, each geometrically textured boss including a mounting base mountable to the support plate and a protruding body adapted to protrude from the lower material contact surface. The method then assembles the plurality of geometrically textured bosses into a textured pattern on the lower material contact surface of the support plate. The method then connects the plurality of geometrically textured bosses to the support plate in a fixed relationship within the textured pattern. Attached Figure Description

[0007] Figure 1 It is a side elevation view of a mobile paver with a floating screed assembly that moves in the direction of travel to produce a homogeneous paving mat on the working surface.

[0008] Figure 2 This is a front perspective view of a leveling assembly, which includes a leveling extender extending laterally from the leveling frame and multiple textured leveling plate assemblies attached to the underside of the leveling frame.

[0009] Figure 3 This is a perspective view of the lower side of a textured flat panel assembly according to the present disclosure, the textured flat panel assembly having a plurality of protruding geometrically textured bosses connected to and protruding from a flat lower material contact surface.

[0010] Figure 4 This is a perspective view of an example of a polyhedral textured boss suitable for bonding to a flat lower material contact surface to produce a textured flat panel assembly.

[0011] Figure 5 This is a perspective view of an example of a triangular or triangular faceted textured boss suitable for connection to a flat material contact surface.

[0012] Figure 6This is a perspective view of an example of a pentahedral textured boss suitable for attaching to a flat, lower material contact surface.

[0013] Figure 7 This is a perspective view of an example of a diamond-textured boss suitable for connection to a flat, lower material contact surface.

[0014] Figure 8 It is a perspective view of a prominent, geometrically textured boss in the shape of a truncated cone.

[0015] Figure 9 It is a perspective view of a prominent geometrically textured boss in the shape of a spherical teardrop.

[0016] Figure 10 It is a perspective view of a prominent geometrically textured boss in the shape of a polyhedral pyramid.

[0017] Figure 11 It is a perspective view of a prominent geometrically textured boss in the shape of a cone or pyramid.

[0018] Figure 12 This is a flowchart of a method for producing a flat plate with a textured pattern by connecting multiple geometrically textured bosses to the flat underside of a support plate.

[0019] Figure 13 It is a perspective assembly view of the lower side of the support plate and the geometrically textured boss with cooperative alignment features.

[0020] Figure 14 It is a perspective view of a geometrically textured boss suitable for fastening to the lower material contact surface by multiple fasteners. Detailed Implementation

[0021] Referring now to the accompanying drawings, where possible, the same reference numerals will denote the same elements, Figure 1An example of a mobile paver or paver 100 is shown for laying paving material 102 on the ground, subgrade, or another working surface 104 to create a paving mat 106, which is laid on and covers the working surface, thereby creating a paved surface. The finished paved surface can be used as a road, highway, structural foundation, or other surface, possessing hardness, smoothness, and durability characteristics to withstand repeated vehicle traffic and varying weather conditions, including temperature changes and precipitation. To distribute paving material 102 on the working surface 104, the mobile paver 100 can be self-propelled and operated to travel in a direction of travel 108 aligned with the longitudinal axis or orientation of the paver. As used herein, the term "forward" or "front" may refer to the forward direction of the mobile paver 100 as it travels in the direction of travel 108, and the terms "backward," "rearward," or "rearward" may refer to the rearward direction of the mobile paver.

[0022] To accommodate and hold paving material 102 before it is distributed onto the working surface 104, the mobile paver 100 may include a hopper 110 supported on a machine frame or chassis 112 that serves as the load-bearing structural support and frame for the paver. The hopper 110 may be an open box-like structure or container including upwardly extending sidewalls 114 that are laterally opposed to and contain the paving material 102 stored therein. The hopper 110 may be located at the front end of the mobile paver 100 and may receive the paving material 102 from above via a transport vehicle such as a dump truck. The hopper 110 may be periodically replenished with fresh paving material delivered from an asphalt plant or facility as paving material is distributed from the mobile paver 100.

[0023] To guide loose, granular paving material rearward from the hopper 110, the mobile paver 100 includes a conveying system 116 extending through and supported by a chassis 112. The conveying system 116 may include one or more conveyor belts that translate about rotating pulleys or rollers to move the paving material 102 rearward and discharge it from the mobile paver 100 onto the work surface 104.

[0024] To advance the mobile paver 100 across the working surface 104 during paving operations, the chassis 112 may be supported on a plurality of ground engagement elements 118 that guide and transmit traction and propulsion forces to the working surface 104. An example of a ground engagement element 118 may be a continuous track, which serves as a belt around a plurality of drive sprockets that can rotate relative to the chassis 112. The continuous track translates relative to the chassis 112 to move the mobile paver 100 across the working surface 104. Another example of a ground engagement element 118 may be a rotatable wheel with a journal attached to the chassis 112.

[0025] To generate power and drive the ground engagement element 118, the mobile paver 110 may include an engine 120 supported on a chassis 112. The engine 120 may be a conventional internal combustion engine that burns hydrocarbon-based fuels to convert the lateral chemical energy therein into power for propulsion and other operations. The engine 120 may also be associated with a generator 122 to generate electricity to power the electrical system of the mobile paver 100. In other possible configurations, the mobile paver 100 may include an electric powertrain and may be operatively driven by multiple batteries or fuel cells.

[0026] To accommodate the operator for steering and controlling the mobile paver 100, the operator station 124 or operator cab may be located on top of the chassis 112, providing visibility above the working surface 104. The operator station 124 may contain various controls and input control devices 126, such as a steering wheel for changing the direction of travel 108 of the mobile paver 100, accelerator and brake pedals, gear shifters and reversing devices, etc. For visual interaction with the operator, the operator station may include an instrument console 128 with various dials, readers, displays, etc. Furthermore, the input control devices 126 and the instrument console 128 may be associated with an electronic controller configured or programmed to receive and process data and information to aid in the operation of the mobile paver 100.

[0027] To distribute the paving material 104 more evenly, a leveling assembly 130 can be attached to the rear end of the chassis 112, which can move over the deposited paving material 102 by the forward travel of the mobile paver 100 in the travel direction 108. The leveling assembly 130 can be associated with a auger conveyor 132, located behind and below the conveying system 116, and arranged to guide and move the loose paving material 114 discharged from it laterally toward the side of the chassis 112. The auger conveyor 132 is arranged on an axis in the lateral direction 134 or perpendicular to the forward and backward travel directions 108, and is perpendicular to the longitudinal axis of the chassis 112. Furthermore, the auger conveyor 132 is vertically adjacent to the working surface 104 and establishes a vertical direction 135 perpendicular to both the travel direction 108 and the lateral direction 134. The auger pusher 132 can be an elongated rotating structure with oppositely oriented helical or spiral blades that laterally push the paving material 104 outward as it rotates.

[0028] To compress and smooth the granular paving material 102 laterally dispensed by the auger conveyor 132, the leveling assembly 130 includes one or more leveling plates 136 attached to the underside of the leveling frame 138. The leveling plate 136 is a metal plate adapted to contact and slide on the paving material 102 deposited on the work surface 104, and the weight and load of the leveling frame 138 compresses the loose paving material 102 into a denser, harder paving mat 106. As an example, the material of the leveling plate 136 may be cast nickel or hardened steel.

[0029] To increase the compressive force applied to the paving pad 106, the leveling frame 138 may include an internal eccentric counterweight that generates a vibratory force in the vertical direction 135, causing the slab 136 in contact with the paving material 102 to vibrate. To prevent the paving material 102 from cooling and adhering to the slab 136, the leveling assembly 130 may be associated with an induction heater located within the leveling frame 138.

[0030] To adjust the thickness of the paving mat 106, the leveling assembly 130 can be pivotally connected to the chassis 112 via one or more drawbars 140. The drawbars 140 are pivotable, allowing the leveling frame 138 to be pivotally tilted relative to the chassis 112 to adjust the angle of attack, or the angle at which the leveling plate 136 meets and contacts the paving material 102 leaving the conveyor system 116 and arriving at the work surface 104. Adjusting the angle of attack allows the leveling plate 136 to move and slide on the paving material 102, thereby allowing the leveling assembly 130 to float relative to the work surface 104. To raise and lower the leveling assembly 130 vertically 135 to contact and disengage from the work surface 104, one or more extendable and retractable hydraulic lifting cylinders 141 can also be connected between the chassis 112 and the leveling frame 138.

[0031] refer to Figure 2 The leveling assembly 130 can extend in the lateral direction 134 to adjust the lateral width of the leveling frame 138. For example, the leveling frame 138 may include a main leveling section 142 and first and second extended leveling sections 144 positioned toward opposite sides of the leveling assembly 130. The extended leveling sections 144 may be located behind the main leveling section 142, and these structures may be slidably connected together, for example, by a sliding dovetail track. In another configuration, the extended leveling sections 144 may be mounted toward the front of the leveling frame 138 relative to the direction of travel 108.

[0032] The leveling assembly 130 may further include a hydraulically actuated extension cylinder 146 that operatively connects the main leveling section 142 to the first and second extended leveling sections 144. Actuation of the extension cylinder 146 causes the first and second extended leveling sections 144 to move relative to the main leveling section 142 in a lateral direction 134. To maintain the lateral distribution of the paving material 104, the first and second extended leveling sections 144 may each include a lateral flange 148 or blade parallel to and aligned with the travel direction 108.

[0033] The leveling plate 136 can be removably attached to the underside of the main leveling section 142 and the first and second extended leveling sections 144. A plurality of leveling plates 136 can extend across the lateral width of the leveling frame 138 to create a continuous, smooth, flat paving mat 106 that spans the lateral direction 134 and extends rearward toward the leveling assembly 130 in the travel direction 108.

[0034] The front portion of the leveling frame 138 may also include a forward panel extending upward from its intersection with the leveling plate 136, which may be configured as a solid planar panel extending in the lateral direction 134. The front portion of the leveling frame 138 pushes excess paving material 102 discharged from the conveying system forward in the travel direction 108 until the material flows under the leveling plate 136 and is compressed by the leveling plate. The leveling assembly 130 may also include a tamping bar adjacent to the front portion of the leveling frame 138, which can move rapidly and repeatedly up and down in the vertical direction 135 to tamp and compact the paving material flowing under the leveling plate 136.

[0035] refer to Figure 3 In this disclosure, the slab 136 can be assembled from components arranged to improve the compaction of the paving material and the formation of the paving mat. For example, to function as a structural frame and support, the slab 136 may include a support plate 150, which is flat and planar in shape and may have a rectangular profile or perimeter. The support plate 150 can be manufactured by a casting process, in which molten metal is poured into a mold of the desired shape and cooled to harden. Examples of suitable metals include high-carbon steel, nickel alloys and chromium carbide steel, cast iron, hardened aluminum-zinc alloys, and other materials with sufficient hardness and strength to prolong physical contact and interaction with the paving material. Other possible materials for the support plate may include ceramics and plastics.

[0036] To conform to a flat planar shape, the support plate 150 may have a lower material contact surface 152 and an upper attachment surface 154 opposite to the lower material contact surface. When the slab plate 136 is attached to the leveling frame, the lower material contact surface 152 is oriented to contact the paving material moving beneath it, and the upper attachment surface 154 is in abutment contact with the leveling frame. As shown, the lower material contact surface 152 may be flat and planar, but in possible variations, the lower material contact surface may include structural features for enhancing interaction with the paving material. The upper attachment surface 154 may be flat and planar, but in some configurations, the upper attachment surface 154 may include mounting and attachment features to secure the slab plate 136 to the leveling frame.

[0037] The lower material contact surface 152 and the upper attachment surface 154 may extend between the front edge 156 and the rear edge 158 of the rectangular profile of the plate casting 150. The terms front edge 156 and rear edge 158 refer to the travel direction 108 of the mobile paver and reflect the movement of the slab 136 relative to the working surface.

[0038] The forward front edge 156 and the rearward rear edge 158 may be linear and parallel to each other in the lateral direction 134. The distance between the forward front edge 156 and the rearward rear edge 158 corresponds to the longitudinal length of the slab 136 and may extend together with the length of the leveling frame in the travel direction 108. To help guide the paving material under the slab 136, the forward front edge 156 may be slightly upturned in the vertical direction 135.

[0039] The rectangular profile or perimeter of the plate casting 150 may also include parallel first and second side edges 160, 162 extending between a front front edge 156 and a rear rear edge 158. The distance between the first and second side edges 160, 162 corresponds to the width of the flat plate 136 in the lateral direction 134. The first and second side edges 160, 162 may be linear and flat to seamlessly abut against the side edges of adjacent flat plates 136 when attached to a flattening frame.

[0040] To improve the mixing of paving material passing under the slab 136, a three-dimensional textured pattern 164 can be included on the lower material contact surface 152 of the support plate 150. The three-dimensional topology of the textured pattern 164 has structural variations with respect to the vertical direction 135. The structural inhomogeneity and morphological variations of the textured pattern 164 can cause displacement of larger aggregates within the paving material. The movement and displacement of the paving material caused by the structure of the textured pattern 164 can further embed aggregates into fine particles and binders, resulting in a denser and harder paving mat. Furthermore, the additional mixing caused by the textured pattern 164 can make the consistency of aggregates and fine particles within the paving material 102 more homogeneous, thereby also improving the properties of the resulting paving mat 106.

[0041] To create the structure of the textured pattern 164, a plurality of geometrically textured bosses 166 can be mounted to an additional flat lower material contact surface 154 of the support plate 150. The plurality of geometrically textured bosses 166 can be arranged in a random or organized pattern and can be spaced apart to create a plurality of corresponding guide grooves 168 located between the geometrically textured bosses. The arrangement of the protruding elements 166 and the guide grooves 168 creates a variable height with respect to the vertical direction 135. For example, the geometrically textured bosses 166 can each have a three-dimensional structural shape protruding from the lower material contact surface 154, including a spatial extension with respect to the vertical direction 135.

[0042] For example, each of the plurality of textured bosses 166 may have a mounting base 170 adapted to attach to the lower material contact surface 152 and a protruding body 172 extending from the mounting base 170. The protruding body 172 may extend to a protruding tip 174 spaced apart from the mounting base 170 with respect to a vertical direction 135. The distance between the mounting base 170 and the protruding tip 174 may define a body height 176 of the textured boss 166 in the vertical direction 135. The textured bosses 166 may be formed differently from the support plate 150, for example by casting metal, and the mounting base 170 may be coupled to the lower material contact surface 152 by an assembly process.

[0043] To connect the textured boss 166 adjacently to the support plate 150, the mounting base 170 may be operatively associated with a structural joint 178. The structural joint 178 may be used to securely hold the textured boss 166 within a defined position on the textured pattern 164 on the support plate. For example, in embodiments where the support plate 150 and the textured boss 166 are made of cast metal, the structural joint 178 may be a weld bead or brazed bead formed accordingly by welding or brazing processes. The structural joint 178 may extend around the periphery of the mounting base 170 at its intersection with the lower material contact surface 156, such that the materials of the support plate 150 and the textured boss 166 are integrally joined or formed together. The structural joint 178 connecting the textured boss 166 to the support plate 150 may be produced by applying a thermal, laser welding, or chemical process. In another example, the structural joint 178 may be formed by a strong adhesive or bonding agent located between the geometrically textured boss 166 and the lower material contact surface 152 of the support plate 150.

[0044] In possible variations, structural joint 178 may be removable to allow the geometrized boss 166 to be separated from the flat plate, such as a threaded fastener. In another example, the fastener may be more permanent, such as a rivet.

[0045] Mounting base 170 serves as a base or cover area, and protruding body 172 corresponds in shape to the contour or periphery of mounting base 170. Mounting base 170 may be smooth and flat to adjacently contact and abut against the corresponding smooth and planar lower material contact surface 152 of the full plate 150. When mounting base 170 is attached to support plate 150, protruding body 172 may be sized and adapted to project and extend from lower material contact surface 152 in the vertical direction 135. Geometrically textured bosses 166 may have any suitable three-dimensional shape for interacting with paving material. Moreover, each of the plurality of geometrically textured bosses 166 may have the same shape, such as Figure 3 The textured pattern 164 in the image can be different in geometry. For example, see reference 164. Figure 4 The geometrically textured boss 166 can be a three-dimensional polyhedron with multiple planes interacting along straight edges and along sharp vertices.

[0046] In the example, the polyhedral boss 180 can be shaped as a diamond or rhombus, including a tetrahedral base 182 with four intersecting edges 184. Associated to and extending from each edge 184 of the tetrahedral base 182 are flat and planar two-dimensional side faces 186. The side faces 186 may intersect the rhombus base 182 at inward angles and may be tapered toward a flat planar apex face 188. The apex face 188 may be parallel to the tetrahedral base 182 and may correspond in shape to the tetrahedral base, such that the rhombus boss 180 is geometrically constructed as a prism.

[0047] In an embodiment, the shape of the polyhedral boss 180 can be established on the main diagonal 190 of a rhombic base 182 extending between two opposite vertices. The rhombic base 182 may also include a secondary diagonal 192 intersecting the main diagonal 190 perpendicularly. The main diagonal 190 is longer than the secondary diagonal 192, such that the rhombic base 182 has an elongated length greater than its width. Moreover, the opposite vertex associated with the main diagonal 190 may be angularly smaller than the corresponding vertex associated with the secondary diagonal 192.

[0048] The polyhedral boss 180 may include a front boss edge 194 and a rear boss edge 196 extending between the rhomboid base 182 and the apex face 188 and formed by the intersection of two side faces 184. The front boss edge 194 may be aligned with the main diagonal 190. When the polyhedral boss 180 is attached to the lower material contact surface 152, the front boss edge 194 is oriented toward the forward front edge 156 of the support plate 150, and the rear boss edge 196 is oriented toward the rearward rear edge 158 of the support plate 150. Moreover, the front boss edge 194 and the rear boss edge 196 may extend at a smaller or shallower angle relative to the rhomboid base 182, and thus have a longer overall dimension than the side boss edge 198, which may be aligned in association with the shorter secondary diagonal 192 of the rhomboid base 182.

[0049] refer to Figure 5 In this example, the polyhedral boss can be triangular or triangular in shape, referred to herein as a triangular-faceted boss 200, having a triangular base 202 with three edges 204 and three side faces 206 extending therefrom. The three side faces 206 can extend to and intersect with a apex face 208, which is parallel to and corresponds in shape to the triangular base 202, such that the triangular-faceted boss 200 is a geometric prism. Furthermore, the three side faces 206 can be angled inwards relative to the triangular base 202 and converge toward the apex face 208, such that the triangular-faceted boss 200 has a tapered structure.

[0050] In the example, the triangular boss 200 may be a geometrically isosceles triangle and may have a longer front boss edge 210 formed along two intersecting side surfaces 206 and orthogonal to the shorter rear boss base 212. When coupled to the lower material contact surface 152 of the plate 136, the front boss edge 210 may be oriented toward the forward front edge 156 of the support plate 150, and the rear boss base 212 may be oriented toward the rearward rear edge 158.

[0051] refer to Figure 6 In the example, the polyhedral boss can be a pentahedral boss 220 having a pentagonal base 222 comprising five edges 224, with one of the five side faces 226 extending from each of the five edges. The five side faces 226 can extend to and intersect a flat planar apex 228 parallel to and corresponding in shape to the pentagonal base 222. The five side faces 226 can also be angled inwards relative to the pentagonal base 222, such that the pentahedral polyhedron 220 is generally conical.

[0052] The pentagonal boss 220 may include five boss edges 230 extending between the pentagonal base 222 and the pointed surface 228. In one example, the pentagonal boss 220 may have a regular pentagonal base 222 such that each of the boss edges 230 has the same length, and any one of the five symmetrically similar boss edges 230 may be oriented towards the forward front edge 156 when the pentagonal boss is attached to the support plate 150. In other examples, the pentagonal base 222 may be irregular and asymmetrical in shape, and the five boss edges 230 may have different lengths. The asymmetrical pentahedral boss may be mounted in a suitable orientation to the lower material contact surface 152 of the support plate 150 to reduce friction and resistance and facilitate sliding interaction with the paving material.

[0053] refer to Figure 7 In the example, the polygonal boss can be a trapezoidal boss 240 having a tetrahedral trapezoidal base 242 with four edges 244, where two edges may be parallel and two edges may not be parallel. Extending from each of the four edges 244 can be a trapezoidal side 246, which intersects with a flat, planar apex 248 that corresponds in shape and is parallel to the trapezoidal base 242. The four side 246 are oriented inward relative to the trapezoidal base 242, such that the trapezoidal boss 240 is a conical prism.

[0054] Due to the non-parallel edges 244, the trapezoidal boss 240 may include a front end 250 and a relatively positioned rear end 252. The front end 250 may be shorter in dimension than the rear end 252. When the trapezoidal boss 240 is attached to the support plate 150, the front end 250 may be oriented towards the forward edge 156 to first encounter the paving material. The shorter width provided by the front end 250 allows the trapezoidal boss 240 to encounter less resistance during operation when the structure moves through and displaces the paving material.

[0055] refer to Figure 8 In the example, the geometrically textured boss can have a circular, rounded, or curved shape, rather than being geometrically constructed as a polygonal structure. For example, a curved boss 260 can have a circular base 262 circumscribed by a circumferential edge 264. The circumferential edge 264 can be a closed curve extending 360° and intersecting itself as a circle. Extending from the circumferential edge 264 can be cylindrical or conical sidewalls 266, which intersect and terminate at a flat planar apex surface 268. The apex surface 268 can be parallel to the circular base 362 and can correspond to the circular base in a circular shape, such that the curved boss 260 is geometrically constructed as a prism. To make the curved boss 260 conical, the conical sidewalls 266 converge radially inward relative to the circular base 262 and can be truncated by the apex surface 268.

[0056] The circular or rounded shape of the curved boss 260 creates a symmetrical geometry that allows the curved boss 260 to be attached in any orientation relative to the front edge 156 and rear edge 158 of the support plate 150. In other examples, the curved boss 260 may have an oval or elliptical mounting base and corresponding geometry. Asymmetrical curved bosses can be mounted in a suitable orientation to the lower material contact surface 152 of the support plate 150 to reduce friction and resistance and promote sliding interaction with the paving material.

[0057] For example, refer to Figure 9 The diagram illustrates a geometrically textured boss 270 constructed in the shape of a teardrop or spherical boss, exhibiting an asymmetrical curved geometry. The teardrop-shaped boss 270 may have a flat planar mounting base 272, outlined by a geometrically shaped curved edge 274. Extending from the curved edge 274 are corresponding curved surfaces or sidewalls 276 intersecting the flat planar apex surface 278. The apex surface 278 is parallel to the mounting base 272 and corresponds in shape to it, such that the teardrop-shaped boss 270 is a three-dimensional prismatic structure.

[0058] The teardrop-shaped boss 270 may include a forward or front boss edge 280 corresponding to the intersection of the curved sidewall 276 on itself. The front boss edge 280 may be angularly positioned relative to the mounting base 272 such that the forward-pointing portion of the curved sidewall 276 near the front boss edge 280 tapers between the curved edge 274 and the pointed surface 278. When the teardrop-shaped boss 270 is attached to the lower material contact surface 152, the front boss edge 280 points towards the forward edge 156 of the support plate 150 to penetrate the paving material and reduce sliding resistance relative to the paving material. To complete the teardrop shape, the teardrop-shaped boss 270 may also include a curved or U-shaped rear end 282 opposite to the front boss edge 280, which extends between the mounting base 272 and the pointed surface 278.

[0059] In addition to being geometrically shaped as a prism, wherein the pointed face 176 is generally parallel to the mounting base 170 and corresponds in shape to the mounting base, the geometrically textured boss 166 can be constructed as a geometric pyramid. The pyramidal boss may be characterized by a mounting base having a specific surface area and one or more sides converging to a common point or apex.

[0060] For example, refer to Figure 10 The diagram illustrates a geometrically textured boss with a pyramidal boss 290, having a polygonal base 292 suitable for mounting to a flat plate and a pointed vertex 294, embodied as a single point, spaced apart from the polygonal base 292. Extending between the polygonal base 292 and the pointed vertex 294 are multiple side faces 296, which may be triangular in shape. The multiple side faces 296 converge angularly from the mounting base 292 toward the pointed vertex 294, giving the pyramidal boss 290 a tapered geometry. The polygonal base 292 can have any suitable shape, and the flat side faces 296 can be provided in any suitable number, allowing the pyramidal boss 290 to have a variety of different geometries.

[0061] refer to Figure 11 The diagram illustrates a geometrically textured boss that corresponds geometrically to a curved or rounded pyramid, such as a conical boss 300. The conical boss 300 may include a circular mounting base 302 having a given surface area and a pointed apex 304 spaced apart from the circular base 302. Extending between the circular base 302 and the pointed apex 304 may be a continuous conical side surface 306. The conical side surfaces converge radially inward between the circular base 302 and the pointed apex 304, such that the conical boss 300 is conical.

[0062] The geometrically textured boss 166 described herein is exemplary, and the geometrically textured boss can have other suitable shapes and configurations sufficient to interact with the paving material to produce a homogeneous and dense paving mat. The shape and configuration of the geometrically textured boss 166 can be selectively designed and adapted to specific paving operations. For example, the geometry of the textured boss 166 can be adapted to engage with a specific composition of the paving material, such as based on aggregate size and binder viscosity. As another example, the body height 176 of the geometrically textured boss 166 can be set to correspond to the depth of the paving mat being produced.

[0063] The textured pattern 164 can be structurally characterized by arranging geometrically textured bosses 166 in a continuous row of lateral bosses 310, which are aligned in the lateral direction 134 parallel to the forward front edge 156 and the backward rear edge 158. For example, as Figure 3 As shown, continuous rows of lateral elements 310 may extend substantially across the lateral width of the support plate 150 between parallel first and second side edges 160, 162. In a particular example, the textured pattern 164 may include a plurality of continuous rows of lateral bosses 310, including a first row of boss elements 312 extending adjacent to and parallel to the forward front edge 156 of the support plate 150 and a second row of lateral bosses 314 located behind the first row of lateral bosses 312 relative to the direction of travel 108. A third row of lateral bosses 316 may be located behind the second row of lateral bosses 314 such that the textured pattern 164 extends toward the rearward trailing edge 158 of the support plate 150.

[0064] In each of the continuous rows of lateral bosses 310, the geometrically textured elements 166 can be laterally spaced from each other in the lateral direction 134, thereby creating a three-dimensional boss pitch 318. The lateral spacing associated with the boss pitch 318 can create channel grooves 168 defined between the plurality of geometrically textured bosses 166. As the lower textured surface 152 moves relative to the working surface, the guide grooves 168 guide the paving material between adjacent protrusions 166. The guide grooves 168 can extend generally along the travel direction 108 across the length of the lower textured surface 152.

[0065] The successive rows 310 of textured patterns 164 can be staggered and offset relative to each other. For example, the textured bosses 166 of the second row 314 can be laterally displaced and offset in the lateral direction 134 relative to a plurality of textured bosses 166 in the first row 312. The textured bosses 166 of the second row 314 are located in the boss pitch 318 of the first row 312, and are therefore distributed among the corresponding textured bosses 166 of the first row 312. The textured bosses 166 of the third row 316 can be aligned with the textured bosses 166 in the first row 312 relative to the direction of travel 108.

[0066] Due to the lateral stagger of the continuous rows 310 of the textured pattern 164, the guide groove 168 can present a curved or zigzag pattern across the lower textured surface 152 as the guide groove extends from the front front edge 156 toward the rear rear edge 158. The curved or laterally displaced pattern of the guide groove 168 facilitates the physical manipulation and mixing of the paving material moving through it.

[0067] In an embodiment, to facilitate a smooth paving pad, the flat slab 136 may include a lateral leveling strip 320 positioned adjacent to the rearward edge 158 of the lower textured surface 152. The lateral leveling strip 320 may be located behind the textured pattern 164 in the direction of travel 108. The lateral leveling strip 320 may be characterized by the absence of any protruding elements 166 and guide grooves 168 of the textured pattern 164, and thus have a flat planar construction. The lateral leveling strip 320 may occupy the remaining 15% to 33%, particularly the remaining 20%, of the length of the lower textured surface 152 in the direction of travel 108 of the flat slab 136. The vertical flatness of the lateral leveling strip 320 can be used to further compact and smooth the paving material moving beneath the flat slab 136.

[0068] To attach the flat plate 136 to the leveling frame, the support plate 150 may include one or more attachment devices 322, 324 located on the upper attachment surface 154. The attachment device 322 may be configured as opposing claws extending across the upper attachment surface 154 in the lateral direction 134, wherein a first attachment device 322 is adjacent to the forward front edge 156, and a second attachment device 324 is located near the rearward rear edge 158. The attachment devices 322, 324 can engage and release with corresponding structures on the leveling frame to releasably attach the flat plate 136. In addition to the claw-like configuration, the attachment devices 322, 324 may utilize different connection techniques and structures to attach the flat plate and the leveling frame.

[0069] Industrial applicability refer to Figure 12Referring again to the preceding figures, an exemplary flowchart of a method and process for manufacturing a slab plate 136 having a textured pattern 164 for physically manipulating aggregate paving material during paving operations is shown. Aspects of the manufacturing process 400 shown can be performed in a manufacturing facility or industrial plant to mass-produce the slab plate 136 on an industrial scale. Aspects of the manufacturing process 400 can also be performed in the field to modify and retrofit existing slab plates 136 to incorporate the textured pattern 164 as described herein using a flat, planar lower material contact surface 154. Additionally, aspects of the manufacturing process 400 can be performed to repair and overhaul the slab plate 136 where the three-dimensional textured pattern 164 has been worn or damaged, for example, during prolonged interaction with the abrasive paving material. For these purposes, repair or retrofit kits comprising multiple geometrically textured bosses 166 and associated hardware can be provided.

[0070] To produce the structural component, manufacturing process 400 may include a plate manufacturing step 402 to produce the support plate 150. For example, the support plate 150 may be cast by introducing molten metal into a mold of a corresponding shape that allows hardening. In another example, the support plate 150 may be machined from existing raw materials during plate manufacturing step 402. Other possible materials suitable for the support plate may include ceramics and plastics. The support plate 150 may also be produced from different materials and processes. The support plate 150 may be manufactured with a lower material contact surface 152 having a flat planar shape.

[0071] Manufacturing process 400 may also include a boss manufacturing step 404 that produces a plurality of geometrically textured bosses 166. In various examples, the boss manufacturing step 404 may produce the geometrically textured bosses 166 by casting steel or metal alloys, or may involve machining with conventional machine tools. Other possible materials suitable for the geometrically textured bosses may include ceramics and plastics. In some examples, the geometrically textured bosses 166 themselves may be assembled from one or more sub-components.

[0072] Manufacturing process 400 may then involve an assembly step 408, in which the support plate 150 and a plurality of geometrically textured bosses 166 are assembled together to create a textured pattern 164 located on the lower material contact surface 152. The textured pattern 164 may arrange and organize the plurality of geometrically textured bosses 166 in a sequential manner between the leading edge 156 and the trailing edge 158 of the entire plate 136, such as... Figure 3As shown in the diagram. The organized textured pattern 164 can produce an interlaced and laterally displaced arrangement of guide grooves 168 formed between the geometrically textured bosses 166. In other configurations, for example, when the platen 136 is assembled in the field during a retrofit operation, the positions of the geometrically textured bosses 166 in the textured pattern 164 can be random. Assembly step 408 may involve placing mounting bosses 170 of the plurality of geometrically textured bosses 166 adjacent to the flat, planar lower material contact surface 152 of the support plate, such that protruding bodies 172 protrude from the lower material contact surface 152, and protruding apexes 174 are vertically spaced from them in the vertical direction 135. Markings may be provided or included on the lower material contact surface 152 to aid in the placement of the plurality of geometrically textured bosses 166 in the textured pattern 164.

[0073] To secure and fasten the plurality of textured bosses 166 arranged on the support plate 150, assembly step 408 may include mounting and coupling operations 410 or sub-steps. Mounting and coupling operations 410 may utilize various techniques. For example, in coupling operation 412, the textured bosses 166 may be physically coupled to the lower material contact surface 152 of the support plate 152. In a particular example, coupling operation 412 may utilize welding or brazing operations, in which the metallic textured bosses 166 are structurally coupled to the material of the support plate 150, with or without filler material, as is customary. Coupling operation 412 may create a structural joint 178 between the textured bosses 166 and the support plate 150, such as... Figure 3 As shown in the diagram. In another example, the bonding operation 412 can utilize an adhesive or glue to connect the geometrically textured boss 166 and the support plate 150.

[0074] In another example, the mounting and coupling step 410 can utilize alignment features to align the geometrically textured bosses 166 relative to the textured pattern 164 and facilitate their coupling to the support plate 150. Alignment of the geometrically textured bosses 166 can be achieved through alignment operation 414. Alignment operation 414 helps generate the textured pattern 164, which has an organized arrangement of multiple geometrically textured bosses 166, such as a continuous row.

[0075] refer to Figure 13In this example, to create the alignment feature 416, the support plate 150 may include a plurality of alignment recesses 418 disposed in the lower material contact surface 152. The alignment recesses 418 may be empty spaces cast or machined into the support plate 150, accessible from the lower material contact surface 152, and corresponding in shape to the geometrically textured boss 166. For example, if the geometrically textured boss 166 is rhomboid or constructed as a polyhedron, the plurality of alignment recesses 418 may each be shaped as diamonds or polygons of similar shape and size protruding into the lower material contact surface 152 of the support plate 150.

[0076] To utilize the alignment feature 416, each geometrically textured boss 166 is oriented toward a corresponding alignment recess 418, wherein the mounting base 170 faces the lower material contact surface 152. The profile of the mounting base 170 may correspond to the shape of the alignment recess 418, such that the geometrically textured boss 166 can be inserted therein and form a sliding fit. The depth of the alignment recess 418 may be dimensioned to accommodate the mounting base 170, wherein the protruding body 172 protrudes beyond the lower material contact surface 152. The geometrically textured boss 166 accommodated in the alignment recess 418 may be structurally coupled to the support plate 150, for example, by engagement operation 412.

[0077] The advantage of alignment feature 416 is that it maintains the orientation of the plurality of geometrically textured bosses 166 within the textured pattern 164. For example, in the case where the geometrically textured bosses 166 include front boss edges and rear boss edges, these features can be correctly oriented and aligned relative to the front front edge 156 and the rear trailing edge 158 of the support plate 150. Alignment feature 166 can also maintain the desired spacing of the plurality of geometrically textured bosses 166 within the textured pattern 164 to produce the desired shape and arrangement of the guide grooves 168. Therefore, alignment feature 416 facilitates the assembly of the entire plate 136.

[0078] In another example, the textured boss 166 can be removed from the support plate 150. For example, if the protruding body 172 of the individual textured boss 166 is worn or damaged, the part can be removed and replaced as part of the fastening operation 420. For ease of removable attachment, refer to... Figure 14 The textured boss may include one or more fastener holes 422 provided in the structure of the mounting base 170. The fastener holes 422 may be cylindrical holes or openings configured to receive threaded fasteners 424, which may engage with corresponding threaded openings provided in the lower material contact surface 152 of the support plate 150. In a fastening operation 420, threaded bolts 424 may secure the textured boss 166 to the support plate 150 with a textured pattern 164, and may be unthreaded to allow for removal of the textured boss 166 if needed.

[0079] In one embodiment, the mounting base 170 may include a peripheral edge 426 or flange projecting laterally relative to the protruding body 172. Fastener holes 422 may be located in the peripheral edge 426 for accessibility. In another embodiment, fastener holes 422 may be provided within the structure of the protruding body 172. Fastener holes 422 may include countersunk holes to receive fastener heads and prevent interference with and damage to the paving material during sliding contact. Using fasteners 424 to attach the geometrically textured boss 166 to the support plate 150 facilitates the retrofitting of existing flat plate 136 during maintenance.

[0080] It should be recognized that the foregoing description provides examples of the disclosed systems and techniques. However, it is conceivable that other embodiments of this disclosure may differ in detail from the foregoing examples. All references to this disclosure or examples thereof are intended to refer to the specific examples discussed at the time and are not intended to imply any limitation on the scope of this disclosure in a more general sense. All distinctions and adverse statements regarding certain features are intended to indicate that such features are not preferred, but are not intended to completely exclude such features from the scope of the invention unless otherwise specified.

[0081] Unless otherwise indicated herein, the descriptions of value ranges herein are intended solely as a shorthand for referring to each independent value falling within the range, and each independent value is incorporated into the specification as if described separately herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or clearly contradicted by the context.

[0082] In the context of describing the invention (especially in the context of the following claims), the terms “a” and “an” and “the” and “at least one” or the terms “one or more” and similar references should be interpreted to cover both the singular and the plural, unless otherwise stated herein or explicitly contradicted by the context. The use of the term “at least one” followed by a list of one or more items (e.g., “at least one of A and B” or “one or more of A and B”) should be interpreted to indicate the selection of one item (A or B) from the list or any combination of two or more of the list items (A and B), unless otherwise stated by the context or explicitly contradicted by the context.

[0083] Therefore, as permitted by applicable law, this disclosure includes all modifications and equivalents to the subject matter set forth in the appended claims. Furthermore, unless otherwise indicated herein or clearly contradicted by the context, this disclosure covers any combination of the foregoing elements and all their possible variations.

Claims

1. A screed plate for a screed assembly towed by a mobile paver, comprising: A support plate, the support plate including a front edge, a rear edge, an upper attachment surface extending between the front edge and the rear edge, and a lower material contact surface adapted to compact and compress paving material sliding under the slab. A plurality of geometrically textured bosses can be mounted to the support plate, each of the plurality of geometrically textured bosses including a mounting base adapted to be placed adjacent to the support plate and a protruding body adapted to protrude from the lower material contact surface; as well as A structural connector that connects one or more of the plurality of geometrically textured bosses to the support plate.

2. The flat plate according to claim 1, wherein the structural joint comprises one or more of weld beads, brazing beads, adhesives, and fasteners.

3. The flat plate according to claim 1, wherein the geometrically textured boss is a geometric prism, comprising a pointed top surface that is substantially opposite to and corresponds in shape to the mounting base.

4. The flat plate according to claim 3, wherein the geometrically textured boss is a polyhedral boss.

5. The flat plate according to claim 4, wherein the polyhedral boss is one or more of a rhomboid boss, a triangular boss, a pentahedral boss, and a trapezoidal boss.

6. The flat plate according to claim 3, wherein the geometrically textured boss is a curved boss.

7. The flat plate according to claim 1, wherein the plurality of geometrically textured bosses are arranged in a textured pattern, the textured pattern having a continuous row of lateral bosses on the support plate, the continuous row of lateral bosses being substantially parallel to the front edge and the rear edge.

8. The flat plate of claim 7, wherein the textured pattern includes a plurality of guide grooves defined between the plurality of geometrically textured bosses, the plurality of guide grooves being generally orthogonal to the front edge and the rear edge.

9. The flat plate of claim 8, wherein the continuous rows of lateral bosses are staggered, and each of the plurality of guide grooves is laterally displaced between the front anterior edge and the rear posterior edge.

10. A method for manufacturing a flat plate with a textured pattern, the textured pattern being used to physically manipulate a paving material, the method comprising: A support plate is manufactured, the support plate having a front edge, a rear edge, an upper attachment surface, and a lower material contact surface opposite to the upper attachment surface; Multiple geometrically textured bosses are manufactured, each geometrically textured boss including a mounting base that can be mounted to the support plate and a protruding body adapted to protrude from the lower material contact surface; The plurality of geometrically textured bosses are assembled on the lower material contact surface in a textured pattern; as well as The plurality of geometrically textured bosses are connected to the support plate in a fixed relationship within the textured pattern.

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