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US-20260125561-A1 - EMULSION AND PAVING MATERIAL

US20260125561A1US 20260125561 A1US20260125561 A1US 20260125561A1US-20260125561-A1

Abstract

An emulsion includes water; asphalt; an emulsifier in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion; a polyolefin having a weight average molecular weight (M w ) of from about 500 to about 30,000 Da; and a copolymer having at least two repeating units wherein a first repeating unit is a styrene residue, and a second repeating unit is a butadiene residue.

Inventors

  • Yonghong Ruan
  • Guiyang Zhu
  • Shaomin Chen
  • Scott M. Hacker
  • Swapnil KANAUJIA
  • Anand Shankar S Mahadware
  • Vidya Gupta

Assignees

  • HONEYWELL INTERNATIONAL INC.

Dates

Publication Date
20260507
Application Date
20251006

Claims (20)

  1. 1 . An emulsion comprising: water; asphalt; an emulsifier in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion; a polyolefin having a weight average molecular weight (M w ) of from about 500 to about 30,000 Da; and a copolymer having at least two repeating units wherein a first repeating unit is a styrene residue, and a second repeating unit is a butadiene residue.
  2. 2 . The emulsion of claim 1 wherein the copolymer is styrene-butadiene rubber.
  3. 3 . The emulsion of claim 1 wherein the polyolefin has a weight average molecular weight of from about 1000 to about 10,000 Da.
  4. 4 . The emulsion of claim 1 wherein the polyolefin has a density of from 0.85 to about 1.00 g/cc, according to ASTM D-1505.
  5. 5 . The emulsion of claim 1 wherein the polyolefin is a homopolymer.
  6. 6 . The emulsion of claim 1 wherein the polyolefin is polyethylene.
  7. 7 . The emulsion of claim 1 wherein the emulsifier is cationic.
  8. 8 . The emulsion of claim 1 wherein the water is present in an amount of from about 20 to about 60 wt %, based on a total weight of the emulsion.
  9. 9 . The emulsion of claim 1 wherein the asphalt is present in an amount of from about 30 to about 79 wt %, based on a total weight of the emulsion.
  10. 10 . The emulsion of claim 1 wherein the emulsifier is present in an amount of from about 0.5 to about 1 wt %, based on a total weight of the emulsion.
  11. 11 . The emulsion of claim 1 wherein the polyolefin is present in an amount of from about 0.1 to about 5 wt %, based on a total weight of the emulsion.
  12. 12 . The emulsion of claim 1 wherein the copolymer is present in an amount of from about 0.1 to about 5 wt %, based on a total weight of the emulsion.
  13. 13 . The emulsion of claim 1 that is an O/W emulsion wherein the asphalt is present as oil droplets and the oil droplets have a Dv90 diameter of from 0.1 to about 20 microns, measured according to ASTM D5861.
  14. 14 . The emulsion of claim 1 that is a W/O emulsion wherein the water is present as water droplets and the water droplets have a Dv90 diameter of from 0.1 to about 20 microns, measured according to ASTM D5861.
  15. 15 . The emulsion of claim 1 exhibiting a viscosity of from about 10 to about 500 seconds, measured at a temperature of from about 25° C. to about 50° C., according to AASHTO T72.
  16. 16 . The emulsion of claim 1 exhibiting an elastic recovery of from about 20 to about 70%, measured according to AASHTO T301.
  17. 17 . A method of forming an emulsion comprising the steps of providing water; providing asphalt; providing an emulsifier; providing a polyolefin having a weight average molecular weight (M w ) of from about 500 to about 30,000 Da; providing a copolymer having at least two repeating units wherein a first repeating unit is a styrene residue, and a second repeating unit is a butadiene residue; and combining the water, the asphalt, the emulsifier, the polyolefin and the copolymer to form the emulsion; wherein the emulsifier is present in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion.
  18. 18 . A paving material comprising: a. an emulsion comprising water, asphalt, an emulsifier in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion, a polyolefin having a weight average molecular weight (M w ) of from about 500 to about 30,000 Da, and a copolymer having at least two repeating units wherein a first repeating unit is a styrene residue, and a second repeating unit is a butadiene residue; and b. an aggregate.
  19. 19 . The paving material of claim 18 wherein the aggregate is present in an amount of from about 80 to about 99 wt %, based on a total weight of the paving material.
  20. 20 . The paving material of claim 18 wherein the aggregate is present in an amount of from about 85 to about 90 wt %, based on a total weight of the paving material.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application claims the benefit of U.S. Provisional application No. 63/716,296, filed on Nov. 5, 2024, the entire content of which is hereby incorporated by reference. TECHNICAL FIELD The present disclosure generally relates to an emulsion and a paving material. More specifically, this disclosure relates to an emulsion including asphalt, an emulsifier, a particular polyolefin, and a particular copolymer. BACKGROUND Asphalt (bitumen) is commonly used as a paving material for road construction and maintenance. Typically, asphalt, often referred to as “asphalt binder” or “asphalt cement,” is mixed with aggregate to form material used in asphalt paving. Processing and use of this material by paving crews yields asphalt pavement. The asphalt pavement includes aggregate held within a continuous phase of the asphalt binder by adherence of the asphalt binder to the aggregate. The strength and durability of the asphalt pavement depends on various factors such as the properties of the materials used, the interaction of the various materials, the mix design, construction practices and the environment and traffic conditions to which the pavement is exposed. To produce a mix that will have good performance during the lifetime of the pavement, it is important to attain proper coating of the aggregate with the asphalt with good adhesion of the asphalt onto the aggregate, good cohesive strength of the asphalt, flexibility of the asphalt, and resistance to external conditions, e.g. UV exposure, drastic temperature changes, etc. Asphalt emulsions have been used worldwide in preventive and corrective maintenance projects on various types of pavement structures, such as highways, expressways, city roads, bus lanes, county roads, airports, etc. In order to obtain better field performance, sometimes various types of polymers are used in asphalt emulsions, e.g., in polymer-modified asphalt emulsions or simply modified asphalt emulsions. During the production stage, most specifications for polymer-modified asphalt emulsions include elastic recovery, softening point, viscosity, stability, etc. During application, there are additional requirements such as chip retention, rutting resistance, abrasion resistance, UV light stability, etc. Elastomer-modified asphalt emulsions can provide elastic recovery but generally have high viscosity, low softening point, low chip retention, and poor UV light stability. On the other hand, plastomer-modified asphalt emulsions have low viscosity, high softening point, high chip retention, and good UV light stability, etc., but minimal elastic recovery. Accordingly, there remains opportunity for improvement. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description of the disclosure and the appended claims. BRIEF SUMMARY This disclosure provides an emulsion including water; asphalt; an emulsifier in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion; a polyolefin having a weight average molecular weight (Mw) of from about 500 to about 30,000 Da; and a copolymer having at least two repeating units wherein a first repeating unit is a styrene residue, and a second repeating unit is a butadiene residue. This disclosure further provides a method of forming the emulsion including the steps of providing the water; providing the asphalt; providing the emulsifier; providing the polyolefin; providing the copolymer, and combining the water, the asphalt, the emulsifier, the polyolefin and the copolymer to form the emulsion; wherein the emulsifier is present in an amount of from about 0.5 to about 5 wt %, based on a total weight of the emulsion. Furthermore, this disclosure provides a paving material including the emulsion and an aggregate. DETAILED DESCRIPTION The following detailed description is merely exemplary in nature and is not intended to limit the current composition. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description. Embodiments of the present disclosure are generally directed to polymers, compositions including the same, and methods for forming the same. For the sake of brevity, conventional techniques related to making polymers and such compositions may not be described in detail herein. Moreover, the various tasks and process steps described herein may be incorporated into a more comprehensive procedure or process having additional steps or functionality not described in detail herein. In particular, various steps in the manufacture of polymers and associated compositions are well-known and so, in the interest of brevity, many conventional steps will only be described briefly herein or will be omitted entirely without providing the well-known process details. In this disclosure, the terminology “about” can describe values±0.1, 0.5, 1, 2, 3, 4, 5, 6, 7, 8