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US-20260125560-A1 - MIXTURES AND METHODS OF PRODUCING PAVING PRODUCTS USING SAME

US20260125560A1US 20260125560 A1US20260125560 A1US 20260125560A1US-20260125560-A1

Abstract

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.

Inventors

  • Gary Wilson

Assignees

  • Gary Wilson

Dates

Publication Date
20260507
Application Date
20260105

Claims (20)

  1. 1 . A paving block produced using a mixture comprising recycled asphalt pavement particles in an amount of 20 to 80 percent of the mixture by weight, and recycled asphalt shingle particles.
  2. 2 . The paving block as in claim 1 , wherein an amount of recycled asphalt shingle particles is from 5 to 80 percent of the mixture by weight.
  3. 3 . The paving block as in claim 1 , wherein an amount of recycled asphalt shingle particles is from 10 to 40 percent of the mixture by weight.
  4. 4 . The paving block as in claim 1 , further comprising an aggregate material that is not recycled asphalt pavement.
  5. 5 . The paving block as in claim 4 , wherein an amount of the aggregate material that is not recycled asphalt pavement is from 10 to 50 percent of the mixture by weight.
  6. 6 . The paving block as in claim 4 , wherein the aggregate material that is not recycled asphalt pavement is selected from a group consisting of virgin rock, sand, gravel, recycled aggregate materials, crushed glass, crushed concrete, crushed rubble, and crushed seashells.
  7. 7 . The paving block as in claim 4 , further comprising a hard surfacing material.
  8. 8 . The paving block as in claim 7 , wherein an amount of the hard surfacing material is from 2 to 15 percent of the mixture by weight.
  9. 9 . The paving block as in claim 7 , wherein the hard surfacing material is selected from a group consisting of rocks, pieces of metal, synthetic rocks, and a mix thereof.
  10. 10 . The paving block as in claim 7 , containing at least 20 percent by weight of the recycled asphalt shingle particles, at least 25 percent by weight of the recycled asphalt pavement particles, at least 15 percent by weight of the aggregate material that is not recycled asphalt pavement, and at least 2 percent by weight of the hard surfacing material.
  11. 11 . The paving block as in claim 7 , wherein none of the recycled asphalt pavement particles or the recycled asphalt shingle particles or the aggregate material that is not recycled asphalt pavement is larger than 1 inch, and none of the hard surfacing material is larger than ⅜ of an inch.
  12. 12 . The paving block as in claim 7 , wherein the hard surfacing material is on one side of the paving block when loaded first into a preform press mold that subsequently receives the recycled asphalt pavement particles and the recycled asphalt shingle particles.
  13. 13 . The paving block as in claim 7 , wherein the hard surfacing material is placed into compartments of a molding system prior that forms the paving block.
  14. 14 . The paving block as in claim 1 is configured to withstand a compressive force of at least 2,000 pounds per square inch and allowing no more than 4% water absorption.
  15. 15 . The paving block as in claim 1 , wherein the mixture is between a temperature of 200 degrees F. to 425 degrees F.
  16. 16 . The paving block as in claim 15 , wherein in the mixture is transferred to a molding system that applies pressure to the mixture to form the paving block.
  17. 17 . The paving block as in claim 16 , wherein the pressure is at or above 2,000 pounds per square inch.
  18. 18 . A paving block produced using a mixture comprising recycled asphalt pavement particles in an amount of 20 to 80 percent of the mixture by weight, and recycled asphalt shingle particles, wherein the mixture is between a temperature of 200 degrees F. to 425 degrees F.
  19. 19 . The paving block as in claim 18 , further comprising a hard surfacing material on only one side of the paving block when loaded first into a preform press mold that subsequently receives the recycled asphalt pavement particles and the recycled asphalt shingle particles.
  20. 20 . The paving block as in claim 19 , wherein an amount of the hard surfacing material is from 2 to 15 percent of the mixture by weight.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application is a divisional application under 35 U.S.C. § 121 and 37 CFR 1.53(b) based upon co-pending U.S. application Ser. No. 18/120,327 filed Mar. 10, 2023. Additionally, this divisional application claims the benefit of priority of co-pending U.S. application Ser. No. 18/120,327 filed Mar. 10, 2023. The entire disclosure of the prior application is incorporated herein by reference. BACKGROUND Technical Field Without limiting the scope of the invention, its background is described in connection with materials and methods for producing paving blocks. More particularly, the invention describes mixtures and methods for using thereof to mold various paving blocks. In an additional aspect, the invention is in connection with a paving block produced using a mixture for producing paving products. Background Description Up to 11 million tons of post-consumer asphalt, shingle waste is generated annually in North America. A portion of this is processed into RAS (recycled asphalt shingle, which is a powder-like substance resulting from decontamination and grinding of shingles) and diverted successfully into use as a dust suppressant on gravel roads and parking lots, and as an additive in hot mix asphalt. But these uses have significant limitations (low value in the case of dust suppressant, and road specifications issues in the case of hot mix asphalt), and much of the post-consumer asphalt shingle waste ends up being land-filled. An alternative market as a material for use in forming paving blocks could raise the value of RAS and lead toward greater diversion of post-consumer asphalt shingle waste from landfills. A close analog of RAS is RAP (recycled asphalt pavement, which is a gravel-like substance resulting from the milling of road surfaces or the crushing of broken asphalt pavement). Like RAS, RAP is used as an additive in hot mix asphalt, and in fact, is used much more extensively than RAS there. The proportion of RAP that is not used in hot mix asphalt has a lower value use as a gravel substitute, and so waste asphalt pavement is seldom land-filled. However, an alternative market as a material for use in forming paving blocks could raise the value of RAP and lead to a greater proportion of it being used in a higher value use than as a gravel substitute. Asphalt cement (a form of bitumen) is present in both RAS and RAP. It is the binder still present in both materials. RAS typically has a range of 18-24% asphalt cement, whereas RAP has a much lower asphalt cement content, in the range of 5-6%. Asphalt cement is normally the most expensive material in the manufacture of roofing materials or hot mix asphalt, even at the low percentage of 5-6%, and so a recycling use that is able to harness the binder quality of post-consumer asphalt cement may be optimal with relation to material value. The prior art fails to disclose the use of RAS and RAP, along with heat and pressure, as a basis for producing paving blocks. The need exists, therefore, for an improved method and improved components to be used for producing more durable paving blocks. SUMMARY Accordingly, it is an object of the present invention to overcome these and other drawbacks of the prior art by providing a novel mixture for producing paving blocks. It is another object of the present invention to provide a novel method of forming paving blocks using the mixture of the invention. It is a further object of the present invention to provide methods of increasing the use of recycled materials in preparing paving blocks. The present invention provides a mixture for producing paving products comprising recycled asphalt shingles (RAS) and recycled asphalt pavement (RAP) particles. The use of these components to form a resulting composite material provides a material that has considerable strength and durability, and absorbs a minimal amount of water, therefore making it nearly impervious to damage caused by the freeze/thaw cycle. Further, the present invention provides a molded paving block using a mixture for producing paving products comprising RAP and RAS particles that are to be used to construct roads, parking lots, driveways, floors, and the like. The molded paving blocks of the present invention are to be used substantially in the same manner as presently available interlocking blocks. The materials used are preferably recycled materials such as RAS and RAP. However, aggregate, whether virgin aggregate or recycled rock-like materials such as crushed glass, crushed concrete, crushed rubble, crushed seashells, et cetera, may be substituted or partially substituted for the RAP. There are many advantages to using recycled materials, such as the reduction of waste and lower cost of raw materials. The preferred proportional amounts of materials in the composite material include RAP in a proportion of about 35% by mass, RAS in a proportion of about 30% by mass, rock-like material that is not RAP in a proportion of