# US 8,465,843 B2 · Crack resistant coating and method of applying crack resistant coating

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- Number: US 8,465,843 B2
- Document ID: US8465843B2
- Status: Granted
- Kind: B2
- Application number: 13/031,971
- Filed: 2011-02-22
- Published: 2011-06-16
- Granted: 2013-06-18
- Earliest claimed: 2009-08-13
- Assignees: Arr-Maz Products, L.P.
- Applicants: Marvin Keller Exline; Jon Brett Wingo; James Joseph Cunningham; James J. Barnat
- Inventors: Marvin Keller Exline; Jon Brett Wingo; James Joseph Cunningham; James J. Barnat
- Web page: https://patentgrep.com/patent/US8465843B2

## CPC

- E01C 7/185: {Isolating, separating or connecting intermediate layers, e.g. adhesive layers; Transmission of shearing force in horizontal intermediate planes, e.g. by protrusions (E01C7/187 takes precedence; adhesive layers for materials E01C7/35)}
- C08L 95/00: Compositions of bituminous materials, e.g. asphalt, tar, pitch
- C09D 195/00: Coating compositions based on bituminous materials, e.g. asphalt, tar, pitch
- E01C 7/187: {Repairing bituminous covers, e.g. regeneration of the covering material in situ, application of a new bituminous topping (application of thin surface layers with other binders E01C7/35; repairing pavings in general E01C11/005)}
- Y10T 428/249955: Void-containing component partially impregnated with adjacent component
- Y10T 428/249982: With component specified as adhesive or bonding agent
- Y10T 428/249983: As outermost component
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- Y10T 428/31815: Of bituminous or tarry residue
- E01C: CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR (forming roads or like surfaces by compacting or grading snow or ice E01H)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention relates to a method for applying a crack resistant coating on a surface, where the crack resistant coating increases resistance to high vertical and horizontal movements and high shear stresses on the surface. The method comprises the steps of applying a binding material to the surface and applying an aggregate mixture within 15 seconds of applying the binding material to the surface, where the aggregate mixture comprises aggregate particles and an asphalt solution and where the aggregate mixture has a plurality of air voids, and where the binding material fills at least 15% of the air voids in the aggregate mixture (AVFA).

## Claims

### Claim 1

A crack resistant coating disposed on a surface to provide resistance to high vertical and horizontal movements and high shear stresses, the coating comprising:
a first binding material layer disposed on the surface to provide a substantially impermeable moisture barrier to the surface;
a first aggregate mixture layer disposed on the first binding material layer, where the first aggregate mixture layer comprises aggregate and asphalt and where the first aggregate mixture layer is disposed on the first binding material layer within fifteen seconds of the first binding material layer being disposed on the surface, the first aggregate mixture layer providing support and structure to the coating to resist rutting;
a second binding material layer disposed on the first aggregate mixture layer, the second binding material layer further providing another substantially impermeable moisture barrier to the surface; and
a second aggregate mixture layer disposed on the second binding material layer, where the second aggregate mixture layer comprises aggregate and asphalt and where the second aggregate mixture layer is disposed on the second binding material layer within fifteen seconds of the second binding material layer being disposed on the first aggregate mixture layer, the second aggregate mixture layer providing a wear surface of the coating and additional structure and support to the crack resistant coating to resist rutting,
where the first binding material layer comprises binding material and the second binding material layer comprises the same binding material as the first binding material layer or different binding material than the first binding material layer.

### Claim 2 (depends on 1)

The coating of claim 1 wherein the first and second aggregate mixtures comprise a plurality of air voids and where the first and second binding material fills a percentage of the air voids, and wherein the percentage of air voids filled with the first and second binding material is greater than about 15%.

### Claim 3 (depends on 2)

The coating of claim 2 wherein the percentage of air voids filled with the first and second binding material is greater than about 18%.

### Claim 4 (depends on 1)

The coating of claim 1 wherein the crack resistant coating has a depth that is flooded with the first and second binding material, and wherein the depth flooded with the first and second binding material is greater than about 0.38 cm.

### Claim 5 (depends on 4)

The coating of claim 4 wherein the crack resistant coating has a depth that is flooded with the first and second binding binding material, and wherein the depth flooded with the first and second binding material is greater than about 0.46 cm.

### Claim 6

A crack resistant coating disposed on a surface, the coating comprising:
a first layer comprising a first aggregate mixture and a first binding material, where the first aggregate mixture comprises aggregate, asphalt, and a plurality of air voids and where the first binding material fills substantially all of the air voids such that the first layer resists cracking; and
a second layer atop the first layer, the second layer comprising a second aggregate mixture and a second binding material, where the second aggregate mixture comprises aggregate, asphalt, and a plurality of air voids and a sufficient quantity of the air voids are not filled with binding material such that the second layer resists deformation and rutting;
where the first layer is created by first applying the first binding material on the surface and then applying the first aggregate mixture on the first binding material within fifteen seconds and the second layer is created by first applying the second binding material on the first layer and then applying the second aggregate mixture on the second binding material within fifteen seconds and where the first binding material is the same binding material as the second binding material or is different binding material than the second binding material.

### Claim 7 (depends on 6)

The crack resistant coating of claim 6 where the aggregate mixture is applied within 10 seconds of applying the binding material to the surface.

### Claim 8 (depends on 6)

The crack resistant coating of claim 6 where the aggregate mixture is applied within 5 seconds of applying the binding material to the surface.

### Claim 9 (depends on 6)

The crack resistant coating of claim 6 where the first layer has a thickness greater than about 0.38 cm.

### Claim 10 (depends on 6)

The crack resistant coating of claim 6 where the first layer has a thickness greater than about 0.46 cm.

### Claim 11 (depends on 6)

The crack resistant coating of claim 6 where the coating has total air voids comprising the air voids in the first layer and the air voids in the second layer, combined, and where greater than about 15% of the total air voids are filled with binding material.

### Claim 12 (depends on 6)

The crack resistant coating of claim 6 where the coating has total air voids comprising the air voids in the first layer and the air voids in the second layer, combined, and where greater than about 18% of the total air voids are filled with binding material.