PENETRATING PRIME EMULSION

Abstract

A bituminous emulsion that is capable of being used as a penetrating prime emulsion. The penetrating prime emulsion may be capable of penetrating compacted soil without the use of solvent, and may toughen quickly to allow early application of a paved layer on the surface. The bituminous emulsion may comprise bituminous material and an emulsifier comprising octylphenol ethoxylates, and optionally further comprising tallow diamine betaines or other betaines.

Claims

1. A bituminous emulsion comprising: binding material; and emulsifier, the emulsifier comprising octylphenol ethoxylates at a rate of 0.05% to 10% by weight of the bituminous emulsion.

2. The bituminous emulsion of claim 1 further comprising a second emulsifier at a rate of 0.05% to 10% by weight of the bituminous emulsion.

3. The bituminous emulsion of claim 2 where the second emulsifier comprises betaines.

4. The bituminous emulsion of claim 3 where the betaines are methylated tallow alkyl diamine betaines.

5. The bituminous emulsion of claim 3 where the betaines are ethoxylated or polyethoxylated tallow alkyl diamine betaines.

6. The bituminous emulsion of claim 1 where the bituminous emulsion is solvent free.

7. A method of creating and using a penetrating prime emulsion, the method comprising: selecting a binding material; producing an aqueous phase, the aqueous phase comprising an emulsifier, the emulsifier comprising octylphenol ethoxylates at a rate of 0.05% to 10% by weight of the penetrating prime emulsion; and emulsifying the binding material in a range of 5% to 75% binding material phase and 10% to 95% aqueous phase to produce the penetrating prime emulsion.

8. The method of claim 7, the aqueous phase further comprising a second emulsifier at a rate of 0.05% to 10% by weight of the penetrating prime emulsion.

9. The method of claim 8 where the second emulsifier comprises betaines.

10. The method of claim 9 where the betaines are methylated tallow alkyl diamine betaines.

11. The method of claim 9 where the betaines are ethoxylated or polyethoxylated tallow alkyl diamine betaines.

12. The method of claim 7 where the penetrating prime emulsion is solvent free.

13. The method of claim 7 further comprising applying the penetrating prime emulsion to a surface.

14. The method of claim 13 further comprising: waiting three days; and then applying a paved layer to the surface.

15. The method of claim 13 further comprising: waiting one day; and then applying a paved layer to the surface.

16. The method of claim 13 further comprising: waiting 8 hours; and then applying a paved layer to the surface.

17. The method of claim 13 further comprising: waiting one hour; and then applying a paved layer to the surface.

18. The method of claim 7 further comprising testing the penetrating prime emulsion by applying it to a compacted soil specimen.

19. The method of claim 18 further comprising first creating the compacted soil specimen by: separating the aggregate to 100% passing the #8 sieve; adding 5% water to assist compaction; compacting at 100-135 psi or higher; drying out the sample overnight at +100 C; and cooling to room temperature

20. A method of dust control, the method comprising: applying a bituminous emulsion to a surface, the bituminous emulsion comprising binding material and emulsifier, the emulsifier comprising octylphenol ethoxylates at a rate of 0.05% to 10% by weight of the bituminous emulsion.

21. The method of claim 20 where the bituminous emulsion further comprises a second emulsifier at a rate of 0.05% to 10% by weight of the bituminous emulsion.

22. The bituminous emulsion of claim 21 where the second emulsifier comprises betaines.

23. The bituminous emulsion of claim 22 where the betaines are methylated tallow alkyl diamine betaines.

24. The bituminous emulsion of claim 22 where the betaines are ethoxylated or polyethoxylated tallow alkyl diamine betaines.

25. The bituminous emulsion of claim 20 where the bituminous emulsion is solvent free.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0018] The devices and methods discussed herein are merely illustrative of specific manners in which to make and use this invention and are not to be interpreted as limiting in scope.

[0019] While the devices and methods have been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the construction and the arrangement of the devices and components without departing from the spirit and scope of this disclosure. It is understood that the devices and methods are not limited to the embodiments set forth herein for purposes of exemplification.

[0020] In general, in a first aspect, the invention relates to a composition for the production of a bituminous emulsion. The bituminous emulsion may be particularly suited for use in road applications. More specifically, the bituminous emulsion may be suitable for use as a penetrating prime emulsion. The bituminous emulsion may be used as a penetrating prime solution that is essentially solvent free.

[0021] The bituminous emulsion, when applied to a surface, may toughen quickly enough and be suitable for application of a paved layer in less than a week, in less than a few days, in less than a day, or even in less than an hour. The surface may be a granular base, which may be understood to mean divided mineral materials from quarriers, bituminous mix aggregates, milled fragments, clinker or breeze, scoria and slags, and also concrete demolition recycling products, or other surface materials.

[0022] The bituminous emulsion may comprise binding material and an emulsifier. The bituminous material may be asphalt, coal tar, bitumen, resins, other suitable material, or a combination thereof. Within the context of the present invention, the expression “bituminous material” may be understood to mean natural bitumen and bitumens derived from a mineral oil and the resulting mixes thereof. Bitumens obtained by cracking and tars are also considered here as bituminous materials within the meaning of the present invention, and also the mixes which may result therefrom. Blown bitumens—residues of distillation, vacuum distillation, or precipitation, for example obtained by propane precipitation—are examples considered within the context of this invention. Also considered here are bitumens diluted using petroleum solvents, bitumens diluted using vegetable oils, and polymer bitumens. The bituminous materials listed above may be anhydrous, as much as is possible on the industrial production scale in question.

[0023] The emulsifier may be octylphenol ethoxylates and may be used in a quantity of 0.05% to 10% by weight of the emulsion. The octylphenol ethoxylates may be used alone or in combination with betaines, which may also be used in a quantity of 0.05% to 10% by weight of the emulsion. The betaines may preferably be tallow diamine betaines, or may be tallow diamine ethoxylate betaines.

[0024] Specifically, the reaction product for use herein may either be a methylated tallow alkyl diamine betaine or a ethoxylated (or polyethoxylated) tallow alkyl diamine betaine-type surfactant. The betaine-type amphoteric surfactant may be representable by the general formula:

##STR00001##

Where R.sub.1 is an alkyl chain, saturated or unsaturated, containing from 10 to 20 carbon atoms.
Where R.sub.2 can be H, CH.sub.3 or a group —(CH.sub.2CH.sub.2O).sub.p—H
Where R.sub.3 can be CH.sub.3, —(CH.sub.2CH.sub.2O).sub.p—H or R.sub.2
Where R.sub.4 can be H or —CH.sub.2CO.sub.2.sup.− Na.sup.+
Where n is an integer that can be from 0 to 3
Where m is an integer or any number greater than 0
Where p can be an integer number from 1 to 15

[0025] The process for obtaining these surfactants may be as follows: The amine, taken from a precursor of either a methylated tallow alkyl diamine or ethoxylated (or polyethoxylated) tallow alkyl diamine, is reacted with sodium 2-chloroacetate under mild reaction conditions, 75° C.-95° C., which favors fewer side products. The reaction is carried out in either water or a water-glycol blend in the presence of a base (sodium hydroxide) to keep the pH of the reaction mixture between 7 and 9. These reaction conditions afford a high conversion to the betaine-type amphoteric surfactant.

[0026] The bituminous emulsion may be created by first selecting a binding material, which may be asphalt, coal tar, bitumen, resins, other suitable material, or a combination thereof. Second, an aqueous phase may be produced by selecting a primary emulsifier, such as octylphenol ethoxylate, which may be used in a quantity of 0.05% to 10% by weight of the emulsion, and optionally selecting a secondary emulsifier, such as tallow amine betaine or other suitable emulsifiers, which also may be used in a quantity of 0.05% to 10% by weight of the emulsifier. Third, the binding material emulsion may be created by emulsifying the binding material in a range of 5% to 75% binding material phase and 10% to 95% aqueous phase.

[0027] The bituminous emulsion may be suitable for use as a penetrating prime emulsion. The penetrating prime emulsion may be applied to a surface. The emulsion may penetrate the surface, creating an essentially tack free surface. The emulsion may penetrate the surface in less than 1 hour, less than 30 minutes, less than 15 minutes, less than 5 minutes, or most preferably less than 1 minute. The emulsion may toughen quickly, allowing application of a paved layer in less than 3 days, less than 1 day, less than 8 hours, or most preferably less than 1 hour.

[0028] The bituminous emulsion may be tested by applying it to a simulated compacted soil specimen. The simulated compacted soil specimen may be produced according to the following steps: [0029] 1. Separate the aggregate to 100% passing the #8 sieve [0030] 2. Add 5% water to assist compaction [0031] 3. Compact at 100-135 psi or higher [0032] 4. Dry out the sample overnight at +100 C [0033] 5. Cool to room temperature
This compacted specimen may then be used to determine the penetration of the bituminous emulsion. This test may separate the current art from reality for the patents on prime coat material generally fail to penetrate a compacted specimen.

EXAMPLES

[0034] Simulated compacted soil specimens prepared as described above were used to test a variety of emulsions, both with and without fuel oil as a solvent. In each instance, the emulsion was applied to the simulated compacted soil specimen. The time in seconds for the emulsion to soak into the compacted soil specimen was recorded, as was the condition of the cured surface.

[0035] The results of testing with a typical chemistry is shown below:

TABLE-US-00001 Penetra- Nouryon tion RedicoteE-11 1# FO Sec Depth mm Cured Surface 2.0% 30% 231  5 Non Tacky or Adhesive 2.0% 20% 300+ 3 Tacky and Adhesive 2.0% 10% 300+ 2 Very Tacky and Adhesive 2.0%  0% 300+ 1 Very Tacky and Adhesive PG 58-28 Asphalt
As fuel oil is added, eventually the emulsion soaks into the compacted substrate. In this case, E-11 requires up to 30% fuel oil to penetrate the surface in less than 5 minutes. At 20% or less, the surface after full penetration is still tacky or very tacky to the touch (sticky) whereby tires of vehicles will probably pick-up the asphalt layer as traffic drives. This is a typical chemistry used and is considered as state of the art.

[0036] Non-ionic chemistry, specifically ethoxylated nonylphenols, do not work at all:

TABLE-US-00002 Penetration NPE 30 1# FO Sec Depth mm Cured Surface 2.0% 30% 300+ 1 very tacky and adhesive 2.0% 20% 300+ 1 very tacky and adhesive 2.0% 10% 300+ 1 very tacky and adhesive 2.0%  0% 300+ 1 very tacky and adhesive PG 58-28 Asphalt

[0037] Surprisingly, octylphenol ethoxylated was found to work well, without the necessity of fuel oil:

TABLE-US-00003 Octylphenol Penetra- Ethoxylate, tion 30 mol 1# FO Sec Depth mm Cured Surface 1.5% 0% 41 3 Non Tacky or adhesive 1.3% 0% 52 3 Tacky and Adhesive 1.0% 0% 132 1 Very Tacky and Adhesive PG 58-28 Asphalt
Even at lower chemical loadings, the octylphenol ethoxylate penetrates very quickly, almost instantaneously, and at 1.25% or higher, the use of octylphenol ethoxylate creates a suitable surface for repaving.

[0038] Lastly, a combination of emulsifiers was found to be even more preferred. One non-limiting example is as follows:

TABLE-US-00004 Octylphenol Tallow Total Penetra- Ethoxylate, Diamine Emul- tion 30 mol Betaine sifier Sec Depth mm Cured Surface 1.50% 0.50% 2.00% 16 6 Non Tacky or Adhesive 1.13% 0.38% 1.51% 18 4 Non Tacky or Adhesive 0.75% 0.25% 1.00% 27 3 Non Tacky or Adhesive PG 58-28 Asphalt

[0039] The octylphenol ethoxylate and betaine also perform remarkable in dust control applications without the need for fuel oil. Typical dust control dilutions like at 20% solids, penetrate deep with no residual tack:

TABLE-US-00005 Octylphenol Tallow Total Penetra- Ethoxylate, Diamine Emul- tion 30 mol Betaine sifier Sec Depth mm Cured Surface 1.50% 0.50% 2.00% 2 7 Non Tacky or Adhesive PG 58-28 Asphalt

[0040] This is opposed to Nouryon RedicoteE-11, which requires high percentages of fuel oil to perform:

TABLE-US-00006 Penetra- Nouryon tion RedicoteE-11 1# FO % Sec Depth mm Cured Surface 2.00% 20% 52 6 Non Tacky or Adhesive 2.00%  0% 25 2 Tacky and Adhesive PG 58-28 Asphalt

[0041] Whereas, the devices and methods have been described in relation to the drawings and claims, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention.