Paved Surface Crack Repair Using Layered Composite System

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Solution Overview

Problem

Current methods for repairing cracks in paved recreational surfaces, such as tennis courts and running tracks, are either temporary or lead to uneven surfaces due to heaving and bubbling, as they fail to effectively manage stress and moisture-related expansion.

Innovation Solution

A method and system involving a watertight tape layer, a polyester fabric layer impregnated with liquid acrylic adhesive, and a fiberglass sheet to create a flexible and adhesive repair system that alleviates stress and prevents further cracking, while providing a smooth transition and additional adhesive strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a fill material is used to repair cracks, then the repair cost is reduced, but the repair duration is short and the surface becomes uneven due to heaving and bubbling

Engineering Contradiction:

Improverepair costVSAvoidrepair duration and surface smoothness

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The repair system is divided into multiple functional layers: a flexible membrane layer (first layer) that accommodates movement, an adhesive layer (second layer) that bonds layers together, and a fiberglass reinforcement layer (third layer) that provides structural strength. This segmentation allows each layer to perform its specific function, preventing the heaving and bubbling issues that occur with single-material repairs.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining different materials with complementary properties: a flexible membrane material that remains pliable under temperature extremes, an acrylic adhesive that provides strong bonding, and a fiberglass sheet that adds tensile strength. This composite approach creates a durable repair that resists the freeze-thaw cycles causing crack expansion.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If a slip-sheet method is used to allow movement, then stress alleviation is improved, but heaving and bubble formation occur causing surface unevenness

Engineering Contradiction:

Improvestress alleviation and movement capabilityVSAvoidsurface smoothness

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The first layer consists of a flexible membrane material that remains pliable under extreme cold and heat conditions. This thin film allows the repair to accommodate substrate movement and stress changes without cracking or becoming rigid, while its flexibility prevents the heaving and bubbling problems associated with more rigid slip-sheet materials.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If moisture is allowed to seep into gaps, then the repair structure becomes vulnerable, but crack expansion occurs due to freezing pressure

Engineering Contradiction:

Improvemoisture infiltration vulnerabilityVSAvoidcrack resistance

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The flexible membrane layer acts as an intermediary barrier between the crack and the external environment. This layer seals the crack opening, preventing moisture infiltration that would lead to freeze-thaw damage and crack expansion, while still allowing the underlying substrate to move and stress-relieve.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively maintains recreational surfaces by preventing further cracking and ensuring a smooth, functional state, outperforming existing methods by reducing heaving and bubbling issues, thus extending the lifespan of the paved surfaces.

Implementation Method 1

The polyester fabric is impregnated with a second liquid acrylic adhesive. A fiberglass sheet is adhered to at least a portion of the second layer and to the paved surface beyond edges of the second layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

applying a watertight tape over a crack in a paved surface to cover the crack and form a first layer

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 3

The first layer is contacted with a first liquid acrylic adhesive. The first layer is covered with a polyester fabric to form a second layer that adheres to the first layer

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7597503B2Method and system for repairing cracks in a paved surface

Publication Date: 2009.10.06 RITE WAY LLC

AI summary

The present invention relates to a method of repairing a crack in a paved surface. This method involves applying a watertight tape over a crack in a paved surface to cover the crack and form a first layer. The tape is applied with an adhesive. The first layer is contacted with a first liquid acrylic adhesive. The first layer is covered with a polyester fabric to form a second layer that adheres to the first layer. The polyester fabric is impregnated with a second liquid acrylic adhesive. A fiberglass sheet is adhered to at least a portion of the second layer and to the paved surface beyond edges of the second layer to form a transition layer over the edges. Also disclosed is a system for repairing a crack in a paved surface.