Recycled Asphalt Paving Blocks via Heated Auger Molding

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Solution Overview

Problem

Current methods fail to effectively utilize recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) for producing durable paving blocks, leading to significant waste and landfill issues, as they are primarily used as dust suppressants or gravel substitutes, with limited value addition.

Innovation Solution

A novel mixture and method involving RAS and RAP particles, combined with other recycled materials, are heated and molded under pressure to create a composite material that is highly durable and resistant to water absorption, suitable for constructing roads, parking lots, and driveways.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) are used as dust suppressants or gravel substitutes, then waste diversion is achieved, but material value is limited and durability is insufficient for high-value applications

Engineering Contradiction:

Improvewaste diversionVSAvoidmaterial value and durability

Core Design Contradiction:

Loss of substanceVSStrength

Solution Approach 1:

The patent combines RAS and RAP particles with virgin aggregate and asphalt binder to create a composite paving block material. This composite approach transforms low-value recycled materials into a high-strength construction material capable of withstanding traffic loads and environmental conditions, thereby resolving the contradiction between waste diversion and material durability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies heat and pressure parameters during the molding process to transform the physical and chemical properties of the RAS-RAP mixture. Heating activates the asphalt binder and facilitates bonding, while pressure densifies the mixture and creates a robust structural matrix, thereby enhancing the strength and durability of the final product

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If RAS and RAP are landfilled, then waste management is simplified, but environmental impact increases and material value is lost

Engineering Contradiction:

Improvewaste management simplicityVSAvoidenvironmental impact and resource loss

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful environmental factor of landfill waste into a beneficial resource by processing RAS and RAP into durable paving blocks. This transformation eliminates the need for landfilling while creating a valuable construction material, thereby converting environmental harm into economic and ecological benefit

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Loss of substance

If traditional hot mix asphalt methods are used with RAS, then recycling is achieved, but road specification issues arise and value addition is limited

Engineering Contradiction:

Improverecycling utilizationVSAvoidroad specification compliance

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The patent segments the recycled material application into a controlled molding process where RAS and RAP are processed into standardized paving blocks with consistent dimensions and properties. This segmentation allows for quality control and specification compliance that cannot be achieved in continuous hot mix asphalt production, thereby resolving the reliability issue

Inventive Principle:

Principle #1Segmentation

4Strength

If heating and pressure molding is applied to RAS-RAP mixture, then strength and durability are enhanced, but energy consumption increases

Engineering Contradiction:

Improvecompressive strength and durabilityVSAvoidheating and pressure energy consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The patent utilizes the asphalt binder naturally present in RAS and RAP as the binding agent, eliminating the need for additional binder heating and application. The recycled materials themselves provide the binding functionality, reducing the energy required for heating and processing while maintaining product strength and durability

Inventive Principle:

Principle #25Self-service

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 resulting paving blocks exhibit enhanced strength, compressive resistance, and reduced water absorption, making them nearly impervious to damage from freeze/thaw cycles, while also reducing waste and lowering raw material costs through the use of recycled materials.

Implementation Method 1

heated and molded under pressure to create a composite material

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

molded under pressure to create a composite material

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS20250012019A1Systems, mixtures and methods of producing paving products using same

Publication Date: 2025.01.09 WILSON GARY

AI summary

A mixture formed from desired proportions of recycled asphalt shingle and recycled asphalt pavement is disclosed. The methods of molding the mixture into paving blocks, which exhibit properties of high compressive strength and low water absorption, are described. The paving blocks may be used to construct roads, parking lots, driveways, etc. A heated auger system for transferring the mixture to a molding system. The heated auger system can include concentric bodies to form separate concentric chambers, with one chamber receiving a heated fluid therethrough, and the other chamber for transporting the mixture through the auger system for heating by the heated fluid.