Rolled thin asphalt patch

Abstract

The rolled thin asphalt patch is a cost-effective solution for pavement maintenance in roads, walkways, and open spaces. Designed for emergency restoration, it is pre-fabricated for all-season and all-climate use. The patch comprises two main layers: a top asphalt-aggregate mixture and a bottom adhesive bitumen layer, both supported by a non-stick release liner. Manufactured under controlled conditions, it ensures consistent quality and easy installation without specialized tools. Key advantages include long service life, resistance to environmental degradation, surface texture restoration, and reduced maintenance costs. It enables immediate patching in conditions where traditional treatments are impractical. Applications include repairing bituminous, sealing joints, utility covers, drainage structures, and bridge shoulders. The invention supports all pre-fabricated protective and hot / cold asphalt overlays and is compatible with various materials such as quarry and riverbed aggregates, slag, pumice, and different bitumen types (pure, modified, cutback, emulsion), with paper or plastic based release liners.

Description

Rolled Thin Asphalt Patch

[0001] The present invention relates to the fields of road construction, civil engineering, and urban infrastructure development, specifically to protective surface patching technologies using flexible asphalt-based materials.

[0002] Conventional methods for repairing potholes and localized surface distress typically rely on factory-produced hot or cold asphalt mixtures and bagged cold mix asphalt. These materials are not suitable for applications involving thin layers below 2 cm due to poor durability and risks of premature failure such as slippage cracks. Surface treatments like chip seal, slurry seal, and microsurfacing require considerable processing time and are impractical for small-scale applications. Additional issues, such as alligator cracking from subgrade settlement, often require full-depth repairs, which are costly and time-consuming. Existing treatments are also ineffective in emergency scenarios or adverse environmental conditions.

[0003] This invention proposes a pre-fabricated, rolled asphalt patch for rapid, effective, and thin-layer surface repairs. The patch integrates a protective top asphalt layer, adhesive bonding layer, and release liner into a flexible sheet suitable for quick deployment and use even in cold climates (down to 0°C). It ensures high skid resistance, durability under traffic and temperature variations, and minimal installation requirements.

[0004] Traditional patching techniques are not effective for layers under 2 cm. They often fail prematurely, especially under traffic or temperature extremes. Additionally, most solutions demand heavy machinery, curing time, and full-scale treatment even for minor localized damage.

[0005] To address the limitations inherent in conventional surface patching techniques, the present invention introduces a pre-fabricated, thin, rolled asphalt patch that integrates all essential components—namely, a wear-resistant asphaltic surface layer, an adhesive bonding layer, and a removable release liner—into a single, pre-assembled composite structure. The design allows for deployment without the need for specialized tools or heavy machinery.The patch exhibits strong adhesion to existing pavement substrates, even under ambient temperatures as low as 0°C, thereby facilitating year-round application. The top surface layer consists of polymer-modified bitumen combined with angular, high-friction mineral aggregates, ensuring enhanced mechanical strength, durability, and skid resistance. The intermediate adhesive layer enables rapid bonding to the substrate, while the bottom release liner preserves integrity during storage and transportation by preventing premature adhesion.Installation is achieved by removing the release liner and placing the patch directly onto a pre-cleaned, dry pavement surface, optionally supplemented by a light application of tack coat to enhance bonding performance. This user-friendly, modular solution provides a rapid, efficient, and economically viable means of remediating localized surface distress with minimal labor, equipment, or operational disruption.

[0006] Key performance benefits of the proposed rolled thin asphalt patch are summarized as follows:a) Enables ultra-thin patching not possible with traditional methods.b) Can be installed without heavy equipment or skilled labor.c) Offers high mechanical durability and waterproof sealing.d) Applicable under various environmental conditions, including cold weather.e) Cost-effective for small-to-medium surface repairs.f) Immediate readiness for traffic post-installation.

[0007] The components of the Rolled Thin Asphalt Patch structure are illustrated in the diagram, which depicts a layered configuration consisting of:1 – Rolled asphalt patch (entire composite),2 – Top asphalt layer,3 – Adhesive layer, and4 – Release liner.Fig.1

[0008] illustrates schematic diagram of the components of the Rolled Thin Asphalt Patch

[0009] depicts the structure of the rolled asphalt patch. The top layer comprises high-friction mineral aggregates and polymer-modified bitumen. The adhesive layer may be bituminous or synthetic. The release liner is made of paper or plastic to ease deployment. Aggregates may include quarry or riverbed stones, slag, and pumice. Bitumen options include pure, cutback, emulsion, or mastic. The patch is rolled, stored, and deployed with ease, and optionally paired with bituminous primers or adhesive tapes for better edge sealing.Examples

[0010] An example of application involves repairing a cracked pedestrian zone in winter (temperature: 2°C) using the rolled patch. The release liner is peeled off, and the patch is applied directly to the dry, clean surface. A hand roller is used to ensure contact. Traffic is allowed immediately after installation. In another case, a damaged section on a steel pedestrian bridge is patched with this product, enhancing grip and waterproofing performance within minutes, without any heavy tools.

[0011] The invention is applicable in road and pavement maintenance, emergency repairs, waterproof sealing, and surface treatment of pedestrian zones, steel bridges, and urban markings. It is ideal for municipal road agencies, emergency road services, contractors, and infrastructure maintenance in cities with limited access to heavy equipment.

[0012] 1: Rolled asphalt patch2: Top asphalt layer3: Adhesive layer4: Release liner

[0013] No biological material is referenced in this application

[0014]

[0015]

[0016] PTL1:

[0017] NPL1:

Claims

A rolled thin asphalt patch comprising:at least one flexible top layer formed from an asphalt-based mixture for surface protection, optionally a bottom adhesive layer configured for bonding to existing pavement surfaces, and optionally a non-stick release sheet for storage and handling purposes; wherein the patch is pre- fabricated in a controlled manufacturing environment as a flexible or semi flexible sheet, roll, or tile form, with variable dimensions, thicknesses, or reinforcement layers, suitable for use in road maintenance, emergency repair, or surface enhancement applications across diverse climatic conditions.The top layer of the patch according to claim 1 is a protective asphalt-based layer comprising:(a) a binder material selected from pure bitumen, modified bitumen, polymeric binders, resin blends, or thermoplastic elastomers, optionally including adhesion-promoting agents or durability-enhancing additives;(b) a mineral aggregate blend selected from natural or synthetic sources, including but not limited to quarry-derived stones, riverbed sediments, metallurgical slag, pumice, recycled construction materials, ceramic grit, or industrial by-products with sufficient hardness and texture to provide skid resistance and load-bearing properties;wherein the thickness of the top layer is at least 3 mm and may comprise or simulate surface layers such as hot mix asphalt (HMA), chip seal, slurry seal, microsurfacing, pre coated aggregates, or other engineered surfacing technologies.The bottom layer of the patch according to claim 1 is an adhesive or bonding layer with a minimum thickness of 0.5 mm, composed of one or more bonding materials selected from petroleum-derived, bio-based, synthetic, chemical, or hybrid systems, including but not limited to pure bitumen, modified bitumen, cutback bitumen, bituminous emulsions, tack coat formulations, epoxy-based resins, thermoplastics, rubberized adhesives, or functionalized mineral pastes, applied through extrusion, spraying, or lamination.The release sheet of the patch according to claim 1 is selected from plastic films, waxed paper, biodegradable polymer foils, silicone-coated sheets, or other non-adherent liners configured to prevent premature bonding between patch layers during storage, transport, or installation.The rolled thin asphalt patch according to claim 1, wherein the patch is fabricated in roll, flat sheet, tile, mosaic, segmented panel, or modular interlocking formats, and may be tailored in length, width, thickness, color, texture, or application method based on user specification or intended infrastructure conditions.The rolled thin asphalt patch according to claim 1, wherein the patch is configured for installation without the need for heating, mechanical compaction, or curing, and is traffic-ready within 5 to 15 minutes after surface application, making it suitable for urgent or temporary road maintenance, pedestrian safety, or high-friction applications.

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