TW202421893A - Meltable mastic and crack sealant packaging - Google Patents

Abstract

A meltable mastic or crack sealant package including a container including polypropylene, polyethylene, or both; the mastic or crack sealant disposed within the container; and a lid comprising polypropylene, polyethylene, or both, attached to or formed integrally with the container to enclose the mastic or crack sealant within the container.

Description

Fusible Putty and Crack Sealant Packaging

The present invention generally relates to crack sealants and putty packaging. In particular, the present invention relates to fusible crack sealants and putty packaging.

The prior art of the present invention is described with respect to fusible crack sealant packaging.

One example is taught in U.S. Patent Nos. 9,919,854 to Chehovits et al. and 10,220,993 to Chehovits et al., which purportedly disclose a durable consumable packaging system for hot melt materials, and in particular asphalt, wherein the packaging system may include asphalt or an asphalt composition contained within a durable consumable wrap or bag, without the need for an outer protective container. ; wherein the durable consumable wrap or bag comprises a woven or non-woven fiber based material, and in particular a spunbond olefin material, the olefin material comprising a high density polyethylene (HDPE) material; and wherein the durable consumable packaging system provides a simple, cost-effective solution to many of the problems associated with the prior art packaging containers and systems described above, while providing additional benefits to overcome specific problems of packaging and transporting asphalt.

Another example is taught in U.S. Patent No. 9,637,252 to Splinter et al., which purportedly discloses an improved sealant package and method for sealing seams and cracks in pavement and parking lots, wherein a liquid sealant material is poured by volume into a container having a bent sheet and the container is cooled so that the sealant becomes a solid block, wherein the sheet is adhered to the sides of the sealant block so that the sheet forms a container for the sealant; wherein the sheet also serves to release the sealant. wherein the sealant block is placed in a container and the sealant is formed by stacking two or more contained blocks together to form a package of two or more blocks that is self-sealed by a sheet; wherein when the package is placed in a melting kettle, heat migrates through the spaces between individual sealant blocks and allows smaller sealant blocks to melt quickly and evenly, and wherein the sealant and film melt together with the sealant material and are incorporated therein to form a final sealant product.

U.S. Patent No. 9,248,588 to Findley et al. purportedly discloses a fusible crack sealant package comprising a polymeric container and a crack sealant material contained therein, wherein the polymeric container includes a bottom portion, the bottom portion including a rigid base and an upwardly extending rigid side wall terminating in an opening and defining the opening; wherein the rigid base and the upwardly extending rigid side wall operate together to define a container; wherein the rigid cover portion is operably engaged with the bottom portion to close the opening and thereby seal the crack sealant material within the container in a watertight manner; and wherein methods of making and using the fusible crack sealant package are also disclosed.

U.S. Patent No. 8,017,681 to Guymon et al. purports to disclose systems and methods for providing thermoplastic products (including packaging therefor), wherein implementation occurs in connection with packaging of one or more components of the thermoplastic product, wherein the packaging is used to contain the components during storage and/or transportation, and wherein at least a portion of the packaging itself is a component for inclusion into the thermoplastic product. In some embodiments, the entire packaging is allegedly incorporated into the thermoplastic product for use therewith.

Zentner's U.S. Patent No. 6,966,723 purportedly discloses a road repair kit and/or bridge joint repair kit comprising an outer container, a measured amount of a binder material, and an independent and different measured amount of an aggregate material, wherein in a preferred embodiment, the binder material is in a first consumable container (fusible bag) and the aggregate material is also in a second consumable container (fusible bag) inside the first consumable container, and wherein in another preferred embodiment, both the binder and the aggregate are contained in the same consumable container (fusible bag).

Putty packaging generally has the same drawbacks as crack sealant packaging. Polypropylene bags, such as TYVEK® bags, can tear easily, allowing the liquid contents to spill. Such bags allow the putty or crack sealant contained within to flow or deform and require a cooling process prior to stacking on a pallet; furthermore, they may require the use of a cardboard gaylord box to keep it completely contained on the pallet. Furthermore, polypropylene bags degrade when exposed to the elements, exposing the putty or crack sealant contained within.

In addition, rigid polypropylene containers also have the disadvantage that they require a long melting time to ensure that they are completely melted before application. Otherwise, the melted putty or crack sealant containing the partially melted container will be inhomogeneous, resulting in inconsistent product performance and possible clogging of the application wand. Blown polystyrene foam containers are easily impacted and easily peeled off, resulting in garbage and environmental pollution.

Therefore, there is a need for a putty and crack sealant package that addresses the shortcomings of the prior art.

As embodied and broadly described herein, one aspect of the present invention relates to a fusible putty or crack sealant package comprising: a container comprising polypropylene, polyethylene, or both; a putty or crack sealant disposed in the container; and a lid comprising polypropylene, polyethylene, or both, attached to the container or integrally formed with the container to seal the putty or crack sealant within the container. In one aspect, the putty or crack sealant is not mixed within the container. In another aspect, the pellets and the binder are mixed within the container. In another aspect, the putty or crack sealant is mixed prior to being disposed within the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the putty or crack sealant are melted simultaneously. In another aspect, oil has been added to the putty or crack sealant to improve its viscosity.

As embodied and broadly described herein, one aspect of the present invention relates to a method of forming a meltable putty and crack sealant package, comprising: providing a container comprising polypropylene, polyethylene, or both; disposing the putty and crack sealant in the container; and attaching a lid comprising polypropylene, polyethylene, or both to the container or forming the lid integrally with the container to seal the putty and crack sealant in the container. In one aspect, the putty or crack sealant is not mixed in the container. In another aspect, the putty or crack sealant is mixed in the container. In another aspect, the putty or crack sealant is mixed before being disposed in the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the putty or crack sealant are melted simultaneously. In another aspect, the method further comprises adding oil to the putty or crack sealant to improve its viscosity.

As embodied and broadly described herein, one aspect of the present invention is directed to a method of using a meltable putty and crack sealant package, comprising: providing a meltable putty and crack sealant package, comprising: a container comprising polypropylene, polyethylene, or both; the putty and crack sealant disposed within the container; and a lid comprising polypropylene, polyethylene, or both, attached to or integrally formed with the container to seal the putty and crack sealant within the container; heating the meltable putty and crack sealant package to form a molten putty and crack sealant liquid; and applying the molten putty and crack sealant liquid. In one aspect, the putty or crack sealant is not mixed within the container. In another aspect, the putty or crack sealant is mixed within the container. In another aspect, the putty or crack sealant is mixed prior to being disposed within the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the putty or crack sealant are melted simultaneously. In another aspect, the method further includes adding oil to the putty or crack sealant to improve its viscosity.

Cross-reference to related applications

This application claims priority to U.S. provisional application serial number 63/399,334 filed on August 19, 2022, the entire contents of which are incorporated herein by reference.

The following describes an exemplary embodiment of the system of the present application. For the sake of clarity, not all features of an actual implementation are described in this specification. Of course, it should be understood that in the development of any such actual implementation, many implementation-specific decisions must be made to achieve the specific goals of the developer, such as complying with system-related and business-related constraints, which will vary from implementation to implementation. Moreover, it should be understood that such a development effort may be complex and time-consuming but is still a routine task for one of ordinary skill having the benefit of the present invention.

Throughout this specification, reference may be made to the spatial relationships between various elements and the spatial orientations of various aspects of the elements, as such devices are depicted in the accompanying drawings. However, as one skilled in the art will recognize after a thorough reading of this application, the devices, components, apparatus, etc. described herein may be positioned in any desired orientation. Therefore, the use of terms such as "above," "below," "upper," "lower," or other similar terms to describe the spatial relationships between various elements or to describe the spatial orientation of aspects of such elements should be understood to describe the relative relationships between such elements or the spatial orientation of aspects of such elements, respectively, as the devices described herein may be oriented in any desired direction.

Crack sealant formulations vary widely by manufacturer and for their intended specific end-use applications. Generally, crack sealants consist of a base asphalt (bitumen), a polymer or rubber copolymer (e.g., styrene-butadiene-styrene copolymer), a bulking agent, and a reinforcing filler. At most ambient storage and shipping temperatures, crack sealant compositions tend to be in solid form. When used, the crack sealant is heated to a temperature at which it becomes a molten liquid and then applied as a heated liquid by pouring and/or pumping. The molten liquid seeps into and fills the cracks and joints and then, after cooling, immediately resolidifies within the cracks and joints thereby sealing or filling them.

Most crack sealant materials are supplied to the end user in a rectangular corrugated cardboard box lined with a poly bag. When manufactured, the corrugated cardboard box is lined with a poly bag. The molten crack sealant material is poured into the corrugated cardboard box lined with the poly bag. Once the desired amount of crack sealant (e.g., 20 to 60 lbs.) has been poured into the poly bag lined with the corrugated cardboard box, the crack sealant composition is allowed to cool, after which it solidifies and adopts the rectangular shape defined by the interior space of the corrugated cardboard box.

This type of packaging provides certain advantages and disadvantages. Advantageously, the rectangular corrugated cardboard packages can be stacked on pallets and transported to a work site. The corrugated cardboard packages provide a flat surface that can carry identification information. When in use, the polyethylene bags containing the crack sealant can be removed from the corrugated cardboard box and inserted into a melting device along with the crack sealant material so that the polyethylene bags melt and become part of the molten end-use material. The corrugated cardboard boxes can be recycled. Disadvantageously, the corrugated cardboard boxes must be collected at the work site for recycling. Under storm conditions, empty cardboard corrugated boxes may be blown away from their intended staging location. Under wet conditions, the corrugated cardboard boxes may disintegrate before or after the crack sealant has been applied. And the corrugated cardboard boxes are susceptible to damage (e.g., deformation) due to compression (e.g., by the weight of the material itself when stacked).

As used herein, the term "cement" is a general term referring to a composite material used for roads, car parks and the like and consisting of mineral particles of one or more asphalts or one or more resins (which include modifiers such as (for example) polymer-modified asphalt) and a binder. Cement is used to fill larger cracks and potholes and for paving surfaces, including load-bearing surfaces.

As used herein, the term "crack sealant" is a general term referring to materials used to fill and thereby seal cracks and joints in asphalt and cement pavement surfaces. Crack sealants are widely used to fill and thereby seal cracks and joints in highways, streets, parking lots and driveways to prevent water penetration. The use of crack sealants extends the service life of such pavement surfaces. Crack sealant materials are also sometimes referred to in the art by terms such as, for example, hot pot; crack seals; crack sealants; crack sealants; crack filling; crack fillers; joint seals; joint sealants; joint sealants; joint filling; joint fillers; rubberized asphalt; tar; polymer modified asphalt; thermoplastic modified asphalt; para-plastic material; rubber modified asphalt; traffic circle detector sealant; waterproof membrane asphalt; modified asphalt; roof asphalt; cold joint adhesive; marking adhesive; and other asphalt/resin/polymer combinations. Throughout this specification and the accompanying claims, the terms "putty" and "crack sealant" will be used, but each term should be understood to cover all materials having the same general composition, use or properties.

FIG. 1 shows a polypropylene container in which the pellets and the binder are disposed.

Figures 2A and 2B show packages of fusible putty stacked on a pallet.

In one embodiment, a meltable putty package includes a container comprising polypropylene, polyethylene, or both, a pellet and a binder disposed within the container, and a lid comprising polypropylene, polyethylene, or both, attached to the container (e.g., by tying or welding) or integrally formed with the container to enclose the pellet and the binder. The meltable putty package can be made by providing a container comprising polypropylene, polyethylene, or both, such as a corrugated polypropylene or polyethylene container. The pellet is placed in the container and a hot liquid binder is poured on top at about 250 to 270 degrees Fahrenheit, or the pellet and binder are pre-blended together and then placed together in the container. The lid is then closed, sealing off the pellets and the binder, and the meltable putty package can be stacked on a pallet for shipping. The end user then removes the meltable putty package and places it in a melting machine. The container and lid completely melt away and become part of the end product, which can be used at normal operating temperatures of 370 to 400 degrees Fahrenheit.

In another embodiment, a meltable crack sealant package includes a container comprising polypropylene, polyethylene, or both, such as a corrugated container comprising polypropylene, polyethylene, or both, a crack sealant disposed in the container, and a cap comprising polypropylene, polyethylene, or both, attached to (e.g., by strapping or welding) the container or integrally formed with the container to seal the crack sealant. The meltable crack sealant package can be manufactured by providing a container comprising polypropylene, polyethylene, or both, disposing the crack sealant in the container, and attaching a cap comprising polypropylene, polyethylene, or both to the container or integrally forming the cap with the container to seal the crack sealant. Generally, the container will prevent the components from escaping from the container, and in some embodiments, the container is waterproof.

Thus, in at least one embodiment, the present invention includes a container comprising polypropylene, polyethylene, or both; a pellet disposed within the container; and a lid comprising polypropylene, polyethylene, or both, attached to (e.g., by strapping, ultrasonic welding, laser welding, friction welding, high frequency welding, vibration welding, hot plate welding, or hot air welding) the container or integrally formed with the container to enclose the pellet and the binder within the container, the binder being solid below at least 100°F; wherein the polypropylene or polyethylene container is capable of being heated to between about 350°F and about 450°F to form a molten liquid material for application to a pavement surface to seal joints and cracks therein, wherein the polypropylene or polyethylene container and the binder melt simultaneously or substantially simultaneously. Disclosure Any and all aspects of the embodiments of the invention disclosed herein may be present together in any single embodiment unless prevented by physical impossibility.

In any embodiment, the viscosity of the putty or crack sealant can be improved by adding oil to the putty or crack sealant to counteract the rigidity of the container and achieve a better viscosity. Such oils include paraffin oil, hydrocarbon oils (such as KENDEX® MNE), DAE (aromatic rubber base oil), aromatic oils, oils made from various parts of plants (such as RHT120), recycled fuel oils, and recycled motor oils. Generally speaking, each putty or crack sealant formulation intended to be packaged using embodiments of the present invention includes a baseline amount of oil. The amount of oil to be added is about 0.5 to 4.0 times the baseline amount (by volume) already present in the formulation. However, additional oil may also be added to a putty or crack sealant formulation that has no baseline amount of oil. In this case, the amount of additional oil to be added is quantified by the amount of polypropylene or polyethylene contained in the container compared to the amount of putty or crack sealant in the container. For example, if the container represents 0.01% of the raw material in the packaging material, 0.05% oil is added to compensate for the viscosity of the packaging material.

As embodied and broadly described herein, one aspect of the present invention relates to a meltable putty package comprising, consisting essentially of, or consisting of: a container comprising polypropylene, polyethylene, or both; a pellet disposed within the container; a binder disposed within the container; and a lid comprising polypropylene, polyethylene, or both, attached to the container or integrally formed with the container to enclose the pellet and the binder within the container. In one aspect, the pellet and the binder are not mixed in the container. In another aspect, the pellet and the binder are mixed in the container. In another aspect, the pellet and the binder are mixed before being disposed in the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the adhesive are melted simultaneously.

As embodied and broadly described herein, one aspect of the present invention relates to a method of forming a meltable putty package comprising, consisting essentially of, or consisting of: providing a container comprising polypropylene, polyethylene, or both; disposing a pellet in the container; disposing a binder in the container; and attaching a lid comprising polypropylene, polyethylene, or both to the container or forming the lid integrally with the container to enclose the pellet and the binder in the container. In one aspect, the pellet and the binder are not mixed in the container. In another aspect, the pellet and the binder are mixed in the container. In another aspect, the pellet and the binder are mixed before being disposed in the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the adhesive are melted simultaneously.

As embodied and broadly described herein, one aspect of the invention relates to a method of using a meltable putty package comprising, consisting essentially of, or consisting of: providing a meltable putty package comprising: a container comprising polypropylene, polyethylene, or both; a pellet disposed within the container; a binder disposed within the container; and a lid comprising polypropylene, polyethylene, or both, attached to the container or integrally formed with the container to enclose the pellet and the binder within the container; heating the meltable putty package to form a molten putty liquid; and applying the molten putty liquid. In one aspect, the pellet and the binder are not mixed in the container. In another aspect, the pellet and the binder are mixed in the container. In another aspect, the pellets and the binder are mixed before being placed in the container. In another aspect, the container is a corrugated container. In another aspect, the container is waterproof. In another aspect, the container and the binder are melted simultaneously.

It should be understood that the specific embodiments described herein are shown by way of illustration and not as limitations of the present invention. The key features of the present invention may be employed in various embodiments without departing from the scope of the present invention. Those skilled in the art will recognize or be able to ascertain, using only routine experimentation, many equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of the present invention and are covered by the scope of the patent application.

All publications and patent applications mentioned in this specification are indicative of the state of the art to which the invention pertains. All publications and patent applications are incorporated herein by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

When used in conjunction with the term "comprising" in the claims and/or this specification, the use of the word "a" or "an" may mean "one," but it is also consistent with the meaning of "one or more," "at least one," and "one or more than one." The term "or" used in the claims is used to mean "and/or," unless it is expressly indicated that only alternatives are intended or that the alternatives are mutually exclusive, although the invention supports definitions that only refer to alternatives and "and/or." Throughout this application, the term "about" is used to indicate that a value includes the inherent variation of error of the device, the method used to determine the value, or the variation that exists between study subjects.

As used in this specification and claims, the words "comprising" (and any forms of comprising, such as "comprise" and "comprises"), "having" (and any forms of having, such as "have" and "has"), "including" (and any forms of including, such as "includes" and "include"), or "containing" (and any forms of containing, such as "contains" and "contain") are inclusive or open-ended and do not exclude additional unlisted elements or method steps. In any embodiments of the compositions and methods provided herein, "comprising" may be replaced by "consisting essentially of" or "consisting of". As used herein, the phrase "consisting essentially of" requires specified integers or steps and those integers or steps do not materially affect the characteristics or functions of the claimed invention. As used herein, the term "consisting of" is used only to indicate the presence of a recited integer (e.g., features, elements, characteristics, properties, method/process steps, or limitations) or group of integers (e.g., features, elements, characteristics, properties, method/process steps, or limitations).

The term "or combinations thereof" as used herein refers to all permutations and combinations of the items preceding the term. For example, "A, B, C, or combinations thereof" is intended to include at least one of the following: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, combinations containing repetitions of one or more items or terms are expressly included, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, etc. A skilled artisan will understand that there is generally no limit on the number of items or terms in any combination unless otherwise clear from the context.

As used herein, words such as, but not limited to, "about," "substantial," or "substantially" are understood to mean conditions that, when so modified, are not necessarily absolute or perfect but will be considered close enough to one of ordinary skill to warrant that the specified condition exists. The degree to which the description can vary will depend on how much variation can be implemented and still allow one of ordinary skill to recognize the modified feature as having the desired properties and capabilities of the unmodified feature. In general, subject to the foregoing discussion, numerical values herein modified by approximating words such as "about" may vary from the stated value by at least ±1, 2, 3, 4, 5, 6, 7, 10, 12, or 15%.

All devices and/or methods disclosed and claimed herein can be made and executed without undue experimentation in accordance with the present invention. Although the devices and/or methods of the present invention have been described according to specific embodiments, it should be apparent to those skilled in the art that changes can be applied to the compositions and/or methods and the steps or step sequences of the methods described herein without departing from the concept, spirit and scope of the present invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the present invention as defined by the scope of the accompanying patent applications.

Furthermore, no limitations are intended to the details of construction or design shown herein, except as described in the claims below. Therefore, it is evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention. Therefore, the protection sought herein is as described in the claims below.

The systems and apparatus described herein may be modified, added to, or omitted without departing from the scope of the present invention. The components of the systems and apparatus may be integrated or separate. Furthermore, the operations of the systems and apparatus may be performed by more, fewer, or other components. The methods may include more, fewer, or other steps. Additionally, the steps may be performed in any suitable order.

To assist the Patent Office and any reader of any patent that issues based upon this application in interpreting the scope of the claims appended hereto, applicants wish to note that they do not intend for any of the claims appended hereto to incorporate 35 U.S.C. § 112(f) as it existed on the filing date thereof, unless the phrase “means for” or “step for” is expressly used in a particular claim.

In order to more fully understand the features and advantages of the present invention, reference is now made to the detailed description and accompanying drawings of the present invention, in which:

FIG. 1 shows a polypropylene container in which the pellets and the binder are disposed.

Figures 2A and 2B show fusible putty or crack sealant packages stacked on a pallet.

Claims (24)

A fusible putty or crack sealant package comprising: a container comprising polypropylene, polyethylene, or both; a putty or crack sealant disposed in the container; and a cap comprising polypropylene, polyethylene, or both, attached to the container or integrally formed with the container to seal the putty or crack sealant within the container. The packaging of claim 1, wherein the putty or crack sealant is not mixed within the container. The packaging of claim 1, wherein the putty or crack sealant is mixed within the container. The packaging of claim 1, wherein the putty or crack sealant is mixed before being disposed in the container. The packaging of claim 1, wherein the container is a corrugated container. The packaging of claim 1, wherein oil has been added to the putty or crack sealant to improve its viscosity. The packaging of claim 1, wherein the container is waterproof. The packaging of claim 1, wherein the container and the putty or crack sealant are melted simultaneously. A method of forming a meltable putty and crack sealant package, comprising: providing a container comprising polypropylene, polyethylene, or both; disposing the putty or crack sealant in the container; and attaching a cap comprising polypropylene, polyethylene, or both to the container or forming the cap integrally with the container to seal the pellets and the binder in the container. The method of claim 9, wherein the putty or crack sealant is not mixed in the container. The method of claim 9, wherein the putty or crack sealant is mixed in the container. The method of claim 9, wherein the putty or crack sealant is mixed before being disposed in the container. The method of claim 9, wherein the container is a corrugated container. The method of claim 9, wherein the container is waterproof. The method of claim 9, wherein the container and the putty or crack sealant are melted simultaneously. The method of claim 9, further comprising adding oil to the putty or crack sealant to improve its viscosity. A method of using a meltable putty or crack sealant package, comprising: Providing a meltable putty or crack sealant package, comprising: A container comprising polypropylene, polyethylene, or both; Putty or crack sealant disposed in the container; and A lid comprising polypropylene, polyethylene, or both, attached to the container or integrally formed with the container to seal the putty or crack sealant within the container; Heating the meltable putty or crack sealant package to form a molten putty or crack sealant liquid; and Applying the molten putty or crack sealant liquid. The method of claim 17, wherein the putty or crack sealant is not mixed within the container. The method of claim 17, wherein the putty or crack sealant is mixed in the container. The method of claim 17, wherein the putty or crack sealant is mixed prior to being disposed in the container. A method as claimed in claim 17, wherein the container is a corrugated container. The method of claim 17, wherein the container is waterproof. The method of claim 17, wherein the container and the putty or crack sealant are melted simultaneously. The method of claim 17, further comprising adding oil to the putty or crack sealant to improve its viscosity.