Foamed Polymer-Modified Bitumen via Aqueous Dispersion Injection

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Solution Overview

Problem

Existing polymer-modified bitumen (PmB) foaming methods require high temperatures for processing, leading to energy inefficiency, increased emissions, and potential degradation of polymers, while also necessitating the use of stabilizing agents and limiting flexibility in polymer choice, resulting in segregation issues.

Innovation Solution

A process that combines polymer modification and foaming of bitumen in a single step by injecting an aqueous polymer dispersion into a pressurized hot bitumen stream, allowing for stable foamed bitumen production with improved aggregate wetting and reduced processing temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If polymer modification and foaming are performed in separate steps with high temperatures, then foamed bitumen can be produced, but energy consumption increases and polymer degradation occurs

Engineering Contradiction:

Improvefoam stabilityVSAvoidprocessing temperature

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent combines polymer modification and foaming operations into a single integrated process step. The aqueous polymer dispersion is injected directly into the hot bitumen stream, and foaming occurs simultaneously through water injection and pressure reduction, eliminating the need for separate high-temperature polymer modification and foaming steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes rapid parameter changes, specifically pressure reduction, to trigger foam expansion. By reducing pressure from the pressurized state to atmospheric pressure, the foam expands rapidly at lower temperatures, avoiding the need for sustained high-temperature processing that would cause polymer degradation.

Inventive Principle:

Principle #35Parameter changes

2Volume of stationary object

If high processing temperatures are used for foaming, then foam expansion is achieved, but polymer segregation and aging increase

Engineering Contradiction:

Improvefoam volumeVSAvoidpolymer homogeneity

Core Design Contradiction:

Volume of stationary objectVSStability of the object's composition

Solution Approach 1:

The patent exploits the phase transition of water from liquid to vapor through rapid pressure reduction. The injected water undergoes explosive vaporization, providing internal pressure that expands the foam while occurring at relatively low temperatures, thereby preventing polymer segregation and aging that would result from high-temperature processing.

Inventive Principle:

Principle #36Phase transitions

3Duration of action of stationary object

If stabilizing agents are added to improve foam stability, then foam half-life increases, but process complexity and cost increase

Engineering Contradiction:

Improvefoam half-lifeVSAvoidprocess complexity

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The patent employs the water already present in the aqueous polymer dispersion as the foaming agent. This self-service approach eliminates the need for additional stabilizing agents or complex foam generation equipment, as the water vaporization itself provides the necessary expansion and stability mechanisms.

Inventive Principle:

Principle #25Self-service

4Reliability

If aqueous polymer dispersion is injected into hot bitumen, then polymer modification is achieved, but mixing time and energy consumption increase

Engineering Contradiction:

Improvepolymer-bitumen mixing efficiencyVSAvoidmixing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs preliminary action by pre-heating the bitumen to a controlled temperature range (105-230°C) before injection, and pre-preparing the aqueous polymer dispersion. This preliminary heating creates optimal conditions for rapid mixing and foam formation, reducing the actual mixing time required during the process.

Inventive Principle:

Principle #10Preliminary action

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

This method achieves energy-efficient, time-saving, and cost-effective production of foamed polymer-modified bitumen with enhanced stability and aggregate wetting, reducing polymer segregation and aging, and enabling improved asphalt performance.

Implementation Method 1

the water contained in the aqueous polymer dispersion vaporizes and foams the mixed stream to obtain a foamed polymer-modified bitumen

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS12600671B2Process for preparing foamed polymer-modified bitumen compositions

Publication Date: 2026.04.14 BASF SE

AI summary

The invention relates to a process for preparing foamed polymer-modified bitumen compositions and to the use thereof for the production of asphalt. The invention also relates to foamed polymer-modified bitumen compositions obtainable by this process. Furthermore, the invention relates to a process for producing an asphalt composition and to the use thereof in road applications. The process for the preparation of the foamed polymer-modified bitumen composition comprises the following steps: i) Heating and pressurizing a bitumen to obtain a hot flowing bitumen stream, ii) Injecting under pressure an aqueous polymer dispersion into the hot flowing bitumen stream obtained in step i), to obtain a pressurized flowing mixed stream of the bitumen and the aqueous polymer dispersion; iii) Expanding the flowing mixed stream, in particular to atmospheric pressure, such that the water contained in the aqueous polymer dispersion vaporizes and foams the mixed stream to obtain a foamed polymer-modified bitumen.