Asphalt Packaging System Using Consumable Olefin Wrap
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Solution Overview
Problem
Current packaging systems for asphalt and hot melt materials face challenges such as inadequate durability, integrity during transport and storage, generation of waste, and inefficiencies in handling and melting processes, particularly for cold flowable asphalts, leading to issues like contamination, clogging, and increased costs.
Innovation Solution
A durable packaging system using a woven or nonwoven fibrous plastic material, such as plexifilamentary olefin, which provides strength, flexibility, and melatability, eliminating the need for outer protective containers, and ensuring the packaging is entirely consumable and waterproof, with a melting point suitable for asphalt reheating temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging systems are used for asphalt, then the packaging provides basic containment, but the packaging lacks durability and integrity during transport and storage, leading to breaches
Solution Approach 1:
The packaging system uses a composite structure combining a polymeric liner material (such as polyethylene or polypropylene) with an asphalt-composite material. The liner provides waterproofing and containment, while the asphalt-composite material provides structural strength and durability. This composite approach resolves the contradiction by combining materials with complementary properties to achieve both integrity and strength.
Solution Approach 2:
The invention changes the physical and chemical parameters of the packaging materials by selecting polymeric liners with specific melting points lower than asphalt reheating temperatures, and asphalt-composite materials with controlled viscosity and softening characteristics. These parameter changes enable the packaging to maintain integrity at storage temperatures while allowing controlled melting and consumption at processing temperatures, thereby achieving both durability and appropriate strength characteristics.
2Reliability
If durable packaging is used to prevent breaches, then packaging strength is improved, but the packaging generates waste and is not entirely consumable
Solution Approach 1:
The packaging system is designed to be entirely consumable through a process where the polymeric liner and asphalt-composite material are melted down and recovered together. The liner material melts at temperatures below the asphalt reheating temperature, allowing both the packaging and the contained asphalt to be processed simultaneously. This eliminates waste by converting the entire packaging system into usable material rather than discarding it as trash.
Solution Approach 2:
The packaging uses inexpensive polymeric materials (polyethylene or polypropylene) that are designed for single-use in their packaged form but can be recovered through melting. These materials provide sufficient durability for transport and storage but are intended to be consumed during the asphalt processing operation, transforming from a disposable waste product into a recoverable material.
3Ease of manufacture
If the packaging melting point is low for easy consumption, then the packaging is easily meltable, but the packaging lacks durability during storage and transport
Solution Approach 1:
The invention carefully selects polymeric liner materials with specific melting point parameters that fall within a critical range: below the asphalt reheating temperature (to ensure easy consumption) but above the maximum storage and transport temperatures (to ensure durability). This parameter optimization resolves the contradiction by finding the precise melting point window that satisfies both opposing requirements.
Solution Approach 2:
The packaging system exhibits different functional qualities at different temperature conditions: at storage and transport temperatures, the material maintains high strength and durability; at processing temperatures, it transitions to easy melatability. This local quality variation with temperature allows the same material to satisfy both contradictory requirements under different operational conditions.
4Reliability
If outer protective containers are used to maintain integrity, then packaging strength is improved, but the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the outer protective container from the packaging system, relying instead on the inherent strength and integrity of the polymeric liner combined with the asphalt-composite material. This simplification removes unnecessary structural complexity while maintaining reliability through the optimized liner material selection and composition design.
Solution Approach 2:
The polymeric liner material performs multiple functions simultaneously: it provides waterproof containment, structural strength during transport, heat resistance at storage temperatures, and controlled melting at processing temperatures. This multi-functionality eliminates the need for separate outer protective containers, reducing overall packaging complexity while maintaining integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The packaging system prevents breaches during storage and transport, maintains asphalt integrity, reduces waste, and allows for efficient melting without affecting the asphalt's properties, enhancing handling and storage efficiency while being cost-effective and suitable for automated processes.
Implementation Method 1
The packaging material is entirely meltable at standard asphalt reheating temperatures without negatively impacting the melting properties of the asphalt composition
Implementation Method 2
The packaging material is waterproof
Implementation Method 3
The packaging system prevents breaches during storage and transport, maintains asphalt integrity
Data Source
AI summary
Durable consumable packaging systems for hot melt materials, and particularly asphalt. The packaging system can include an asphalt or asphalt composition contained within a durable consumable wrap or bag without the need for an outer protective container. The durable consumable wrap or bag comprises a woven or non-woven fiber based material, and particularly a spun-bonded olefin material, the olefin material comprising a high density polyethylene (HDPE) material. The durable consumable packaging system provides a simple, cost effective solution to a number of the problems associated with the prior art packaging containers and systems described above, while providing additional benefits to overcome the problems specific with the packaging and transport of asphalt.