Pre-fabricated Pothole Patch with Waterproof Seal
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Solution Overview
Problem
Current pothole repair methods often result in temporary fixes due to insufficient compression and curing time of asphalt fill, leading to frequent repairs and high maintenance costs, as well as damage to vehicles, with water intrusion and erosion causing cracks and further damage.
Innovation Solution
A pre-fabricated patch with a wear layer for traction, a structural reinforcement layer to prevent cracking, and a bottom sealing layer to create a waterproof seal, ensuring the filler material can cure without water seepage and withstand vehicular loads, comprising aggregate stone frit, viscous bitumen, and fibrous materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If asphalt fill is placed and compressed to repair a pothole, then the pothole is filled and leveled with the road surface, but the asphalt is prone to develop stress cracks and the repair is only temporary due to insufficient curing time and water intrusion
Solution Approach 1:
The patent applies preliminary action by pre-fabricating a patch with a waterproof membrane and reinforcement layers before the asphalt fill is placed. This patch is installed over the cured asphalt, providing immediate protection against water intrusion and crack propagation, eliminating the need to wait for the asphalt to fully cure before protecting it.
Solution Approach 2:
The patent segments the repair system into distinct functional layers: the asphalt fill layer for structural repair, the waterproof membrane layer for water protection, and the reinforcement layer for crack prevention. This segmentation allows each layer to perform its specific function independently, with the membrane and reinforcement providing protection regardless of the asphalt's curing state.
2Productivity
If asphalt fill is placed without sufficient compression or curing time, then the repair can be applied quickly, but the asphalt develops stress cracks particularly at joint edges adjacent to the surrounding road surface
Solution Approach 1:
The patch with waterproof membrane and reinforcement is prepared in advance and installed immediately over the asphalt fill, providing preemptive protection against stress cracks at joint edges before they can develop from water intrusion or loading.
Solution Approach 2:
The reinforcement layer and waterproof membrane act as a cushioning protection layer that absorbs and distributes stress, preventing stress concentration at the joint edges where cracks typically initiate, thereby protecting the asphalt fill from crack propagation.
3Ease of manufacture
If the interface between asphalt fill perimeter and existing road surface is not sealed, then the repair process is simple, but rainwater collects below the pothole repair surface leading to erosion of the asphalt fill
Solution Approach 1:
The waterproof membrane is pre-installed over the asphalt fill perimeter and integrated with the surrounding road surface before any water intrusion can occur, creating a pre-established seal that prevents rainwater collection and erosion without requiring complex additional sealing steps.
4Reliability
If repetitive repairs are performed at the same locations due to temporary fixes, then the immediate potholes are repaired, but maintenance costs increase over time
Solution Approach 1:
By installing the waterproof membrane and reinforcement layer in advance over the asphalt fill, the system provides long-term protection that prevents the typical failure modes (water intrusion, crack propagation), thereby extending the service life of the repair and reducing the frequency of repetitive repairs.
Solution Approach 2:
The multi-layer patch structure provides beforehand protection against the cumulative effects of weathering and repetitive loading, cushioning the asphalt fill from damage that would otherwise require repeated repairs over time.
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 patch significantly extends the longevity of pothole repairs by preventing crack propagation and water intrusion, reducing maintenance costs and vehicle damage, while maintaining structural integrity under repetitive loads and weather conditions.
Implementation Method 1
a bottom sealing layer to not only form a seal or barrier with the surrounding adjacent road surface to prevent water migration into the repaired pothole
Implementation Method 2
the top surface is made of a material for frictional contact with the tires of oncoming traffic to provide traction similar to the surrounding roadway surface
Implementation Method 3
Disposed in-between the wear layer and the bottom sealing layer is a structural reinforcement layer to prevent the patch from tearing apart
Data Source
Figure 1~3
Figure 4~5
AI summary
A pre-fabricated road patch and method of installation for repair of potholes is disclosed. The patch is placed upon the compacted top surface of a repaired pothole, overlapping onto the adjacent road surface and compressed. The patch forms a water proof seal over the surface area of the patch preventing water from seeping into the repaired pothole.