Application of high toughness, low viscosity nano-molecular resin for reinforcing pothole patching materials in asphalt and concrete base pavement

Abstract

Described herein are methods of improving the durability of concrete by the infusion of the concrete with a low-viscosity oligomeric solution, and subsequent curing of the oligomeric solution to form a high toughness polymer. Also described herein are compositions containing concrete and high toughness polymers, and formed articles made from concrete and high toughness polymers. The methods and compositions are useful for improving the durability of concrete roads and structures, as well as the durability of repairs to concrete roads.

What is claimed is: 
     
         1 . A method of repairing a road pavement, comprising:
 depositing a bottom layer of a pothole repair material within a pothole of the road pavement;   compacting the bottom layer within the pothole;   depositing a top layer of the pothole repair material over the bottom layer;   infusing at least the top layer with a precursor solution, wherein the precursor solution has a viscosity of no greater than 100 cps, and cures in less than 2 hours; and   forming a thermoset polymer from the precursor solution, wherein the thermoset polymer has a toughness of greater than 6.0 ft-lbs/in as measured by Notched Izod Impact ASTM D256.   
     
     
         2 . The method of  claim 1 , wherein the bottom layer is compacted to a porosity level of 8% or less. 
     
     
         3 . The method of  claim 1 , wherein the bottom layer is compacted to a porosity level of 5% or less. 
     
     
         4 . The method of  claim 1 , wherein the bottom layer is compacted such that the top layer is selectively infused with the precursor solution. 
     
     
         5 . The method of  claim 1 , wherein the precursor solution is infused to a depth less than an overall thickness of the top layer and the bottom layer. 
     
     
         6 . The method of  claim 1 , wherein a thickness of the top layer is 5 cm or less. 
     
     
         7 . The method of  claim 1 , wherein the pothole repair material comprises a mixture of asphalt and aggregates. 
     
     
         8 . The method of  claim 1 , wherein the pothole repair material comprises aggregates, and forming the thermoset polymer comprises forming a network of the thermoset polymer extending through interconnected voids among the aggregates. 
     
     
         9 . The method of  claim 1 , wherein the top layer is reinforced by the thermoset polymer to a porosity level of 5% or less. 
     
     
         10 . The method of  claim 1 , wherein the precursor solution comprises a cyclic olefin. 
     
     
         11 . The method of  claim 10 , wherein the cyclic olefin is dicyclopentadiene or norbornene. 
     
     
         12 . The method of  claim 1 , wherein the precursor solution comprises a trimer of a cyclic olefin. 
     
     
         13 . The method of  claim 1 , wherein the precursor solution comprises a ring opening metathesis polymerization catalyst. 
     
     
         14 . The method of  claim 1 , wherein the thermoset polymer is formed by ring opening metathesis polymerization, and the thermoset polymer comprises polydicyclopentadiene or polynorbornene. 
     
     
         15 . The method of  claim 1 , wherein a top surface of the top layer is approximately flush with a top surface of the road pavement. 
     
     
         16 . A dual layer structure for pothole repair, comprising:
 (a) a pothole repair material, wherein the pothole repair material comprises a mixture of asphalt and aggregates arranged in a bottom layer and a top layer over the bottom layer; and   (b) a thermoset polymer;   wherein the thermoset polymer is infused into the pothole repair material to form a network of the thermoset polymer extending through interconnected voids among the aggregates, and   wherein the network of the thermoset polymer extends to a depth less than an overall thickness of the pothole repair material, and is localized in the top layer of the pothole repair material.   
     
     
         17 . The dual layer structure of  claim 16 , wherein a thickness of the top layer is 5 cm or less. 
     
     
         18 . The dual layer structure of  claim 16 , wherein the top layer is reinforced by the thermoset polymer to a porosity level of 5% or less. 
     
     
         19 . The dual layer structure of  claim 16 , wherein the thermoset polymer comprises polydicyclopentadiene or polynorbornene. 
     
     
         20 . The dual layer structure of  claim 16 , wherein the thermoset polymer has a toughness of greater than 6.0 ft-lbs/in as measured by Notched Izod Impact ASTM D256.