Method of producing a composite material using a mixing system

Patent metadata

Field	Value
Publication number	US-9896381-B2
Application number	US-201615255688-A
Country	US
Kind code	B2
Filing date	Sep 2, 2016
Priority date	Jun 24, 2009
Publication date	Feb 20, 2018
Grant date	Feb 20, 2018

Abstract

A method produces a composite material using a mixing system. The composite material comprises at least one aggregate, e.g. rock and/or glass, and the reaction product of a two-component polymeric binder composition comprising a first component, e.g. an isocyanate component, and a second component, e.g. an isocyanate-reactive component. The mixing system includes a mixing apparatus. The method includes the step of providing the aggregate, the first component and the second component into the mixing apparatus. The method further includes the step of mixing the first and second components to produce the reaction product of the two-component polymeric binder composition, and the step of applying the reaction product of the two-component polymeric binder composition to the aggregate within the mixing apparatus to produce the composite material. The composite material can be used for forming a paved structure, such as a sidewalk or a roadway.

First claim

What is claimed is:

1. A mixing system for producing a composite material, the composite material comprising an aggregate and a reaction product of a two-component polymeric binder composition comprising a first component and a second component, said mixing system comprising:
an aggregate vessel for holding the aggregate;
a first vessel comprising the first component;
a second vessel for holding the second component independent from the first component; and
a mixing apparatus comprising a mixer and an auger rotatably disposed within a channel, wherein the mixing apparatus is in communication with the aggregate vessel, the first vessel, and the second vessel, and the mixing apparatus is operable to mix the aggregate with the reaction product of the first component and the second component to produce the composite material;
wherein the mixer of the mixing apparatus is adapted to receive and mix the first component and second component independent of the aggregate to form the reaction product;
wherein the aggregate directly contacts the reaction product in the mixing apparatus to form the composite material.

2. The system of claim 1 , wherein the mixing apparatus further comprises:
a housing defining the channel, with the channel in communication with the mixer and the aggregate vessel and wherein the auger is operable to mix the composite material and dispense the composite material from the channel;
a conveyer disposed between the aggregate vessel and the mixing apparatus, the conveyor is operable for transporting the aggregate from the aggregate vessel into the channel at a delivery rate;
a first pump in fluid communication with the first vessel and a second pump in fluid communication with the second vessel, wherein each of the pumps is also in fluid communication with the mixer;
a controller in communication with the pumps operable for controlling the application rate of the reaction product of the two-component polymeric binder composition to the aggregate within the channel based on the delivery rate of the aggregate into the channel; and
a platform with the aggregate vessel, the first vessel, the second vessel, and the mixing apparatus disposed on the platform, wherein the platform is portable.

3. The system of claim 1 , wherein the first component is an epoxy resin and the second component is a hardener.

4. The system of claim 1 , wherein the first component is an isocyanate and the second component is an isocyanate-reactive component.

5. The system of claim 4 , wherein the isocyanate-reactive component is an alcohol, an amine, or both.

6. The system of claim 1 , wherein the aggregate is about 1 to 99% by weight glass and about 1 to 99% by weight rock each based on the weight of the aggregate.

7. The system of claim 6 , wherein the aggregate has an average diameter of about ⅛ to about ¼ of an inch.

8. The system of claim 1 , wherein the aggregate comprises crumb rubber.

9. The system of claim 1 , wherein the aggregate comprises rock.

10. The system of claim 1 , wherein the reaction product of the two-component polymeric binder composition comprises an isocyanate and a polyol wherein the polyol is in the binder composition in an amount of from about 30 to about 120 parts by weight based on 100 parts by pre-reaction weight of all components in the binder composition except the isocyanate component and wherein the reaction product is the reaction product of the isocyanate and polyol.

11. The system of claim 1 , wherein the aggregate is directly contacted by the reaction product and is coated with a uniform coating of the reaction product of the two-component polymeric binder composition.

12. The system of claim 1 , wherein the mixing apparatus includes a static mixer or an impingement mixer for mixing the first and second components to produce the reaction product of the two-component polymeric binder composition.

Assignees

• Basf Se
• Pervious Paving Contractors Llc
• Previous Paving Contractors Llc

Inventors

• Hicks Steven
• Bower David Kenneth
• Handlos William G
• Kaul Joe
• Arnott Brian T

Classifications

• C04B2111/0075

  for road construction · CPC title

• E01C19/104

  Mixing by means of movable members in a non-rotating mixing enclosure, e.g. stirrers (E01C19/08 takes precedence) · CPC title

• E01C19/50

  Removable forms or shutterings for road-building purposes (E01C23/02, E01C23/04 take precedence; permanent forms E01C3/00 - E01C7/00, {E01C9/00 - E01C17/00} ; slip forms E01C19/48); Devices or arrangements for forming individual paving elements, e.g. kerbs, in situ · CPC title

• C04B14/04

  Silica-rich materials; Silicates · CPC title

• E01C19/1013

  Plant characterised by the mode of operation or the construction of the mixing apparatus; Mixing apparatus; (E01C19/1004, E01C19/1054 take precedence) · CPC title