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US-12624211-B2 - Biobased asphalt rejuvenating emulsion

US12624211B2US 12624211 B2US12624211 B2US 12624211B2US-12624211-B2

Abstract

A polymer-modified emulsion used for rejuvenating or repairing deteriorated asphalt pavement includes an asphalt phase containing an asphalt and a biobased rejuvenating agent, and an aqueous phase including water and an emulsifying agent, and one or more polymers included in the asphalt phase, the aqueous phase or both.

Inventors

  • Gaylon L. Baumgardner
  • Paul A. Morris
  • Joel B. Shealey
  • William E. Grubba

Assignees

  • ERGON ASPHALT & EMULSIONS, INC.

Dates

Publication Date
20260512
Application Date
20220616

Claims (20)

  1. 1 . A polymer-modified asphalt rejuvenating emulsion comprising: a stable liquid dispersion containing an asphalt phase comprising an asphalt composition and about 0.5% to about 15%, based on a total weight of the emulsion, of at least one biobased rejuvenating agent, the asphalt composition containing an asphalt or blend of asphalts having a penetration grade of at least 50 pen; an aqueous phase comprising water and an emulsifying agent; and one or more polymers included in the asphalt phase, the aqueous phase or both, wherein asphalt recovered from the upper 9.5 mm of a pavement having an upper surface treated with the rejuvenating emulsion has a viscosity of about 1,000 to about 3,000 centipoise at 60° C., and a decreased viscosity compared to asphalt recovered from the upper 9.5 mm of a pavement having an upper surface that has not been treated with the rejuvenating emulsion.
  2. 2 . The emulsion of claim 1 , wherein the asphalt phase comprises from about 30% to about 70% of the total weight of the emulsion.
  3. 3 . The emulsion of claim 1 , wherein the at least one biobased rejuvenating agent comprises a biobased oil or ester thereof.
  4. 4 . The emulsion of claim 1 , wherein the at least one biobased rejuvenating agent comprises one or more of a vegetable oil or ester thereof, a seed oil or ester thereof, a soybean oil or ester thereof, a corn oil or ester thereof, a palm oil or ester thereof, a canola oil or ester thereof, a safflower oil or ester thereof, a sunflower oil or ester thereof, a citrus oil or ester thereof, pine oil or ester thereof, a rosin oil or ester thereof, a biobased fatty acid ester, or a combination thereof.
  5. 5 . The emulsion of claim 1 , wherein the at least one biobased rejuvenating agent comprises about 2% to about 15% of the total weight of the emulsion.
  6. 6 . The emulsion of claim 1 , wherein the one or more polymers is an acrylic polymer.
  7. 7 . The emulsion of claim 6 , wherein the acrylic polymer comprises a butyl (meth)acrylate polymer, an ethyl (meth)acrylate polymer or a derivative thereof, a styrene-butyl acrylate copolymer, or an ethylene butyl acrylate copolymer.
  8. 8 . The emulsion of claim 1 , wherein the one or more polymers comprises an elastomer or plastomer.
  9. 9 . The emulsion of claim 1 , wherein the one or more polymers comprises styrene butadiene rubber, styrene-butadiene-styrene or polychloroprene.
  10. 10 . The emulsion of claim 1 , wherein the one or more polymers comprises about 1% to about 15% of the total weight of the emulsion.
  11. 11 . The emulsion of claim 1 , wherein the emulsifying agent comprises from about 0.01% to about 3.0% of the total weight of the emulsion.
  12. 12 . A method for rejuvenating deteriorated asphalt, which method comprises: a) providing a polymer-modified asphalt emulsion comprising a stable liquid dispersion containing an asphalt phase which includes an asphalt composition and about 0.5% to about 15%, based on a total weight of the emulsion, of at least one biobased rejuvenating agent, the asphalt composition containing an asphalt or blend of asphalts having a penetration grade of at least 50 pen, an aqueous phase which includes water and an emulsifying agent, and one or more polymers included in the asphalt phase, the aqueous phase or both; and b) applying the asphalt emulsion to a deteriorated asphalt pavement surface wherein asphalt recovered from the upper 9.5 mm of pavement to which the asphalt emulsion has been applied has a viscosity of about 1,000 to about 3,000 centipoise at 60° C., and has a decreased viscosity compared to asphalt recovered from the upper 9.5 mm of pavement to which the asphalt emulsion has not been applied.
  13. 13 . The method of claim 12 , wherein the asphalt phase comprises from about 30% to about 70% of the total weight of the emulsion.
  14. 14 . The method of claim 12 , wherein the one or more polymers comprise a butyl (meth)acrylate polymer, an ethyl (meth)acrylate polymer, a styrene-butyl acrylate copolymer, or an ethylene butyl acrylic copolymer.
  15. 15 . The method of claim 12 , wherein the at least one biobased rejuvenating agent comprises a biobased oil or ester thereof.
  16. 16 . The method of claim 12 , wherein the emulsifying agent comprises from about 0.01% to about 3.0% of the total weight of the emulsion.
  17. 17 . The method of claim 12 , comprising applying the emulsion to the deteriorated asphalt pavement surface in an amount of about 0.045 to about 2.7 liters per square meter.
  18. 18 . The method of claim 12 , comprising applying the emulsion to the deteriorated asphalt pavement surface at an emulsion temperature of about 4° C. to about 99° C.
  19. 19 . A rejuvenated asphalt pavement comprising a polymer-modified asphalt rejuvenating emulsion atop a deteriorated asphalt pavement, the rejuvenating emulsion containing an asphalt phase comprising an asphalt composition and about 0.5% to about 15%, based on a total weight of the emulsion, of at least one biobased rejuvenating agent, the asphalt composition containing an asphalt or blend of asphalts having a penetration grade of at least bout 50 pen, an aqueous phase comprising water and an emulsifying agent, and one or more polymers included in the asphalt phase, the aqueous phase or both, wherein asphalt recovered from the upper 9.5 mm of pavement under the rejuvenating emulsion has a viscosity of about 1,000 to about 3,000 centipoise at 60° C., and has a decreased viscosity compared to asphalt recovered from the upper 9.5 mm of a pavement not under the rejuvenating emulsion.
  20. 20 . The rejuvenated asphalt pavement of claim 19 , wherein the at least one biobased rejuvenating agent comprises a biobased oil or ester thereof.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application is a continuation of application Ser. No. 15/744,812 filed Jan. 14, 2018 and now allowed, which is a national stage filing under 35 U.S.C. § 371 of International Application No. PCT/US2016/042495 filed Jul. 15, 2016, which claims priority under 35 U.S.C. § 119 to U.S. Provisional Patent Application No. 62/192,930 filed Jul. 15, 2015 and U.S. Provisional Patent Application No. 62/262,701 filed Dec. 3, 2015, the disclosure of each are herein incorporated by reference in their entirety. TECHNICAL FIELD This invention relates to modified asphalt emulsions for road surface treatments. BACKGROUND Asphalt concrete, also known as asphalt pavement, is a composite material that includes mineral aggregate and an asphalt (bitumen) binder which hardens to form a robust surface. Asphalt pavement deteriorates over time from oxidation of asphalt binder, heavy loads and varying climatic conditions. One method for restoring or repairing deteriorated asphalt pavement is to remove and replace the existing pavement with either newly prepared or recycled pavement. Removal and replacement, however, is expensive and wasteful. SUMMARY OF THE INVENTION Rather than removing and replacing deteriorated pavement, it is preferable to restore the pavement using a surface treatment. In one aspect, this disclosure is directed at a polymer-modified asphalt rejuvenating emulsion comprising: an asphalt phase comprising an asphalt and at least one biobased rejuvenating agent;an aqueous phase comprising water and an emulsifying agent; andone or more polymers included in the asphalt phase, the aqueous phase or both. In another aspect, this disclosure provides a method for rejuvenating deteriorated asphalt, which method comprises: a) providing a polymer-modified asphalt emulsion comprising an asphalt phase which includes an asphalt and at least one biobased rejuvenating agent, an aqueous phase which includes water and an emulsifying agent, and one or more polymers included in the asphalt phase, the aqueous phase or both; and(b) applying the asphalt emulsion to a deteriorated asphalt pavement surface. Another aspect of this disclosure is directed to a rejuvenated asphalt pavement comprising a polymer-modified asphalt rejuvenating emulsion atop a deteriorated asphalt pavement, the rejuvenating emulsion containing an asphalt phase comprising an asphalt and at least one biobased rejuvenating agent, an aqueous phase comprising water and an emulsifying agent, and one or more polymers included in the asphalt phase, the aqueous phase or both. The disclosed polymer-modified asphalt rejuvenating emulsions containing biobased rejuvenating agents are suitable for road maintenance of deteriorated asphalt pavement, thereby extending the life and service of the pavement. DETAILED DESCRIPTION The term “about” refers to a range of numbers that is considered equivalent to the recited value (e.g., having the same function or result). In many instances, the term “about” may include numbers that are rounded to the nearest significant figure. The term “biobased” refers to compositions from natural or biological resources, including derivatives or modifications thereof. The term “polymer” includes, independently, homopolymers, copolymers, terpolymers, block copolymers, segmented copolymers, graft copolymers, and any mixture or combination thereof. The term “deteriorated” refers to cracked, aged, oxidized or distressed asphalt pavement, for example distressed includes asphalt pavement identified by Miller, John S., and William Y. Bellinger. Distress identification manual for the long-term pavement performance program. No. FHWA-HRT-13-092. 2014. The term “emulsifying agents” refer to surfactants (including biodegradable surfactants) and to stabilizing agents. Emulsifying agents maintain the asphalt material in a stable suspension and control the emulsion breaking time, where the breaking time is the time required for the emulsified asphalt materials to separate from the aqueous phase permitting water evaporation and formation of a cured or set coating. The term “meth” in parentheses, such as “(meth)acrylate,” refers either to the acrylate or to the methacrylate, or mixtures of both. Similarly, the term (meth)acrylamide refers either to the acrylamide or to the methacrylamide, or mixtures of both. Numerical ranges expressed using endpoints include all numbers subsumed within that range (e.g. 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4 and 5). All percentages are weight percentages. Disclosed is an asphalt rejuvenating emulsion that includes at least one biobased rejuvenating agent in the asphalt phase of the emulsion. Additionally, one or more polymers may be added to either an asphalt phase, the aqueous phase, or both phases of the asphalt rejuvenating emulsion to enable an asphalt pavement surface treatment or an interlayer treatment in conjunction with other treatments. These treatments may be used, for example, a