Sealant Packaging Segmentation for Faster Melting
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Solution Overview
Problem
Existing sealant packaging methods for concrete and asphaltic pavements are costly and inefficient, as foamed polymer containers are expensive and slow to melt, and prior methods using polypropylene film are not applicable for joint sealants and result in slow melting times due to the need to heat large blocks.
Innovation Solution
A method of packaging sealant material in multiple blocks contained by a polypropylene sheet, which acts as an inexpensive container and release liner, allowing for faster and more even melting when stacked and heated in a kettle, with the sheet melting into the sealant mix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamed polymer containers are used to package sealant material, then the container can be melted with the sealant in the kettle on-site, but the melting time is slow and the container is expensive
Solution Approach 1:
The sealant package is divided into multiple individual blocks (typically three blocks) rather than a single large block. This segmentation increases the surface area to volume ratio, allowing heat to penetrate more efficiently and melt the sealant faster. The patent specifically notes that multiple blocks melt approximately two-and-a-half times faster than a single large block of equivalent total weight.
2Device complexity
If a single large block of sealant material is used, then the packaging is simple, but the melting time is slow due to the large solid block requiring extensive heating
Solution Approach 1:
The sealant is packaged as multiple separate blocks within a single container, maintaining packaging simplicity while dramatically reducing melting time through increased surface area exposure to heat.
Solution Approach 2:
Multiple sealant blocks are nested together within a single polypropylene container, allowing them to be handled and transported as one unit while melting as separate blocks for faster heat transfer.
3Ease of manufacture
If polypropylene film is used as packaging, then the packaging is inexpensive and easy to store, but the method is not applicable for joint sealants and results in slow melting times
Solution Approach 1:
The patent uses polypropylene film to package multiple small sealant blocks, combining the cost-effectiveness and storage efficiency of film packaging with the fast melting benefits of segmented blocks.
Solution Approach 2:
The polypropylene film serves multiple functions: it acts as the packaging container, provides a release liner to facilitate easy block removal, and melts with the sealant in the kettle to become part of the final product, making it suitable for joint sealant applications.
4Reliability
If foamed polymer containers are used, then the container can be melted with the sealant, but the container must be separately transported and stored in preparation for the sealant packaging process
Solution Approach 1:
The polypropylene film is integrated directly into the packaging process, serving as both the container and a component that melts with the sealant. This eliminates the need for separate foamed polymer containers and their associated transport and storage preparation.
Solution Approach 2:
The polypropylene film performs multiple functions including packaging, release liner, and melt ingredient, eliminating the need for separate preparation steps required by foamed polymer containers.
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 allows for faster and more even melting of sealant blocks, reducing melting time by approximately two-and-a-half times compared to traditional single-block systems, while also providing a cost-effective and efficient packaging solution.
Implementation Method 1
multiple blocks of sealant are contained by a sheet of polypropylene and form a self-sealed package
Implementation Method 2
When the package is placed in a melting kettle, heat migrates through the spaces between the individual sealant blocks (unlike prior systems which use a single, large block of sealant material), allowing the smaller sealant blocks to melt more quickly and evenly in the kettle
Implementation Method 3
allowing the smaller sealant blocks to melt more quickly and evenly in the kettle
Implementation Method 4
The polypropylene sheet acts as an inexpensive, easily stored container for the sealant, and can also be melted into the sealant mix at the job site
Data Source
AI summary
An improved sealant packaging and method for use with sealing joints and cracks in pavement and parking lots is provided. Liquid sealant material is poured by volume into a container draped with a sheet. Container is cooled so that the sealant becomes a solid block, with the sheet adhered to the sides of the sealant block such that the sheet forms a container for the sealant. The sheet also acts a release liner for easily removing the sealant block from the container. Two or more contained blocks are stacked together, forming a package of two or more blocks self-sealed by sheets. When the package is placed in a melting kettle, heat migrates through the spaces between the individual sealant blocks and allows the smaller sealant blocks to melt quickly and evenly. Sheet and film melt with sealant material and are incorporated therein to form the final sealant product.