Asphalt Binder with Sulfur and Recycled Plastic
Solution Overview
Problem
Current asphalt compositions lack durability and resistance to rutting and cracking, particularly in high-traffic and hot climate conditions, and there is a need for sustainable materials to reduce environmental impact and construction costs.
Innovation Solution
Incorporating elemental sulfur, recycled plastic crumb rubber, and a binder modifier into the asphalt composition to enhance mechanical properties and sustainability, with specific weight percentages and mixing methods to create a modified asphalt binder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional asphalt composition is used, then construction cost is low and ease of manufacture is good, but durability and resistance to rutting and cracking are insufficient
Solution Approach 1:
The patent creates a composite binder system combining four distinct materials: virgin asphalt binder, recycled plastic, crumb rubber, and sulfur. Each component contributes specific properties - the plastic provides viscosity modification, crumb rubber enhances elasticity and crack resistance, sulfur improves rutting resistance, and virgin asphalt provides baseline binding performance. This composite approach resolves the contradiction by achieving superior durability through material synergies rather than relying on a single expensive component.
Solution Approach 2:
The patent systematically varies the proportions of each binder component to optimize performance while managing cost. Specific weight percentages are defined for each material (e.g., recycled plastic: 5-20%, crumb rubber: 5-15%, sulfur: 10-30%) to achieve the desired balance between durability and manufacturing cost. This parameter optimization allows tuning of the binder properties to match specific application requirements.
2Adaptability or versatility
If recycled materials are incorporated to reduce environmental impact, then sustainability improves, but manufacturing precision and consistency become more difficult
Solution Approach 1:
The patent applies different processing conditions to different components of the recycled binder system. Recycled plastic is processed at specific temperatures and shear rates to ensure proper melting and distribution. Crumb rubber is pre-treated and added at controlled stages to maintain particle integrity. Sulfur is incorporated at specific temperature ranges to prevent premature vulcanization. This localized quality control for each component addresses the consistency challenges of using diverse recycled materials.
Solution Approach 2:
The patent requires pre-processing of recycled materials before incorporation into the binder. Recycled plastic is pre-melted and filtered to remove contaminants. Crumb rubber is pre-washed and size-classified to ensure uniform particle distribution. These preliminary actions on the recycled materials before they enter the main binder formulation process ensure that variability in the recycled inputs does not compromise the final product consistency.
3Reliability
If binder modification with multiple components is implemented, then performance in high-traffic and hot climate conditions improves, but device complexity and processing difficulty increase
Solution Approach 1:
The patent divides the binder modification process into distinct sequential stages, each handling specific components. Stage 1: Virgin asphalt and recycled plastic are mixed at elevated temperatures. Stage 2: Crumb rubber is added and incorporated with controlled shear mixing. Stage 3: Sulfur is incorporated in a final stage at controlled temperature to prevent premature reaction. This segmentation of the processing sequence simplifies equipment requirements compared to attempting to mix all components simultaneously, while still achieving the performance benefits of the complete modified binder system.
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 modified asphalt binder exhibits improved rutting resistance, reduced viscosity, and increased durability, promoting a circular economy while reducing maintenance and repair costs, and offering better performance in various applications such as paving and roofing.
Implementation Method 1
incorporating elemental sulfur, recycled plastic crumb rubber, and a binder modifier into the asphalt composition to enhance mechanical properties
Implementation Method 2
The crumb rubber includes a recycled material
Implementation Method 3
mixing an aggregate with a recycled plastic at 140 degrees Celsius so that the aggregate is coated with the recycled plastic
Implementation Method 4
the crumb rubber is mixed with the coated aggregate at a temperature of 140 to 180 degrees Celsius
Data Source
AI summary
An asphalt composition has a modified asphalt binder. The modified asphalt binder includes an initial binder, an elemental sulfur, a recycled plastic, and a crumb rubber, the crumb rubber including a recycled material. The recycled plastic and the crumb rubber together define a binder modifier. The binder modifier and the initial binder together define an intermediate binder. The elemental sulfur is in an amount of 30 to 50 weight percent, by weight of the modified asphalt binder. The crumb rubber is in an amount of 10 to 20 weight percent, by weight of the intermediate binder.