Small-Scale Asphalt Pavement Repair With Separated Aggregate And Binder

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Solution Overview

Problem

Small-scale asphalt repairs using a cooker vehicle result in significant waste materials and increased costs due to the need for producing asphalt mixtures in excess of the required amounts.

Innovation Solution

A method involving spreading aggregates, mixing a binder containing asphalt and a lubricative solidification material with an alkaline additive, pouring the mixture onto the spread aggregate, and curing it to form a paved body, using single-sized crushed stones and specific ratios of components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a cooker vehicle is used to stir and transport guss asphalt mixture, then the mixture can be produced with sufficient fluidity and work efficiency, but a large amount of waste materials is generated and repair costs increase when performing small-scale repairs

Engineering Contradiction:

Improvework efficiencyVSAvoidwaste materials

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The invention divides the asphalt pavement repair process into two independent parts: (1) preparing the aggregate layer by spreading crushed stones directly on the floor slab, and (2) separately preparing and pouring the binder mixture containing asphalt and alkaline additive. This segmentation allows each component to be prepared in precise amounts needed for the specific repair scale, eliminating the requirement to produce large quantities of pre-mixed guss asphalt mixture in a cooker vehicle, thereby reducing waste materials while maintaining work efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts the alkaline additive from the traditional guss asphalt mixture formulation and applies it separately to the aggregate layer during the repair process. This extraction allows the binder mixture to be prepared in smaller, more controlled quantities directly at the repair site, rather than requiring large-scale production in a cooker vehicle, thus reducing waste while preserving the functional benefits of the alkaline additive for adhesion and watertightness.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If a cooker vehicle is used to stir and transport guss asphalt mixture, then the mixture can be produced with sufficient fluidity and work efficiency, but repair costs increase when performing small-scale repairs

Engineering Contradiction:

Improvework efficiencyVSAvoidrepair cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention replaces the expensive and complex cooker vehicle system with simpler, more economical materials and methods suitable for small-scale repairs. By using directly spread aggregates and a separately prepared binder mixture that can be applied without heavy machinery, the method achieves cost-effective repairs while maintaining adequate work efficiency for small to medium-sized repair projects.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If single-sized crushed stone is used as aggregate, then the adhesiveness and watertightness of the paved body are enhanced, but the manufacturing precision requirement increases

Engineering Contradiction:

Improveadhesiveness and watertightnessVSAvoidaggregate size control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention specifies a particular parameter range for the crushed stone aggregate (single-sized with controlled粒径 distribution) to optimize both adhesiveness and watertightness. By defining specific size parameters for the aggregate, the method achieves reliable performance while providing clear manufacturing guidelines that balance precision requirements with practical feasibility.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite structure combining single-sized crushed stone aggregate with a specially formulated binder mixture containing asphalt and alkaline additive. This composite material system enhances adhesiveness and watertightness through the synergistic interaction between the controlled-size aggregate and the chemically active binder, where the alkaline additive specifically reacts with the aggregate surface to improve bonding while the asphalt provides water resistance.

Inventive Principle:

Principle #40Composite materials

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 efficient use of materials based on repair scale, reducing waste and costs, while enhancing adhesiveness and watertightness of the repaired asphalt pavement.

Implementation Method 1

an alkaline additive to and with a binder containing an asphalt and a lubricative solidification material

Methodology Applied

Scientific EffectSaponification:

Implementation Method 2

pouring the binder mixture containing the asphalt into a place where the aggregate is spread

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Data Source

PatentEP4624664A1Method for repairing asphalt pavement

Publication Date: 2025.10.01 MAEDA ROAD CONSTR CO LTD

Figure 1(a)~1(d)

AI summary

Provided is a method for repairing asphalt pavement comprising: a spreading step of spreading an aggregate 20 over a floor slab 1; a mixing step of obtaining a binder mixture 30 by adding and mixing an alkaline additive to and with a binder containing an asphalt and a lubricative solidification material; a filling step of pouring the binder mixture 30 into a place where the aggregate 20 is spread; and a curing step of curing the aggregate 20 and the binder mixture 30 to obtain a paved body.