Asphalt brick device and method of making same

Abstract

The present invention provides an asphalt brick device and method of manufacture, the asphalt brick device used for repairing potholes and other roadway deformities, as provided in the present invention. An additional aspect of the present invention is to provide an asphalt brick device that is of predictable and readily-varied composition that reflects the characteristics of the targeted repair site, ambient conditions, logistical requirements such as delivery and sizing of the material, and operational requirements. Further, the asphalt brick device may be configured to be stackable to satisfy user-defined asphalt repair delivery and ordering requirements.

What is claimed is: 
     
         1 . An asphalt brick device having a predetermined shape, comprising:
 a body having an upper surface, a lower surface, a front surface and a rear surface to define a specific shape;   wherein the body comprises an aggregate and a binding agent of a user-selected relative proportion by one of volume and of weight based on pre-determined calculations;   wherein the aggregate and binding agent are mixable when the body is in a first state;   wherein when the asphalt brick device is adapted to be transportable and stacked.   
     
     
         2 . The device of  claim 1 , wherein the body is configured to operate in a first state and a second state, the first state a moldable state and the second state a solid state. 
     
     
         3 . The device of  claim 2 , wherein the first state operates above a first temperature and the second state operates below a second temperature. 
     
     
         4 . The device of  claim 3 , wherein the first temperature is 250 degree F. 
     
     
         5 . The device of  claim 1 , wherein the aggregate is comprised of at least one of crushed stone, gravel, sand, silt and clay. 
     
     
         6 . The device of  claim 1 , wherein the binding agent is comprised of a bituminous material. 
     
     
         7 . The device of  claim 1 , wherein the binding agent is in the range of 4-8 percent by weight of the mixed aggregate and binding agent. 
     
     
         8 . The device of  claim 1 , wherein the specific shape is of substantially rectangular shape. 
     
     
         9 . The device of  claim 1 , further comprising a textured surface on at least one of the upper surface and the lower surface. 
     
     
         10 . The device of  claim 1 , further comprising at least one protrusion on at least one of the upper surface and the lower surface and at least one conforming void on the opposite of the at least one of the upper surface and the lower surface. 
     
     
         11 . The device of  claim 10 , wherein the protrusion and conforming void enable stacking of the asphalt brick device upon another asphalt brick device. 
     
     
         12 . The device of  claim 10 , wherein the conforming void is on the lower surface and is configured to engage tines of a forklift. 
     
     
         13 . The device of  claim 1 , further comprising a scored portion on at least one of the upper surface and the lower surface, the scored portion enabling a substantially controlled breaking of the body into two pieces substantially along an axis aligned with the scored portion. 
     
     
         14 . The device of  claim 1 , wherein the asphalt brick device weighs no more than 40 lbs. 
     
     
         15 . The device of  claim 8 , wherein the substantially rectangular shape is of approximate dimension 12 inches by 8 inches by 4 inches. 
     
     
         16 . The device of  claim 1 , further comprising a nanoparticle sensor. 
     
     
         17 . The device of  claim 1 , wherein the body is a plurality of bodies wrapped to facilitate transport by a user. 
     
     
         18 . A method for manufacturing a portable asphalt brick device having a predetermined shape and consistency, comprising:
 receiving a quantity of aggregate and a quantity of binding agent based on a pre-determined location of ultimate use;   heating the quantity of aggregate and the quantity of binding agent to a first temperature to form an asphalt mix;   mixing the asphalt mix to obtain a substantially uniform composition;   compressing the asphalt mix into a mold;   forming at least one portable asphalt brick device in the mold;   cooling the at least one portable asphalt brick device below a second temperature.   
     
     
         19 . The method of  claim 18 , wherein the first temperature is 250 degree F. 
     
     
         20 . The method of  claim 18 , wherein the mold is configured to form a plurality of the portable asphalt brick devices comprising at least one protrusion on an upper surface and at least one conforming void on a lower surface of each portable asphalt brick device, the protrusion and conforming void enabling stacking of the asphalt brick device upon another asphalt brick device. 
     
     
         21 . The method of  claim 20 , wherein the mold is configured to form at least one scored portion on the upper surface of each asphalt brick device, the scored portion enabling a substantially controlled breaking of the asphalt brick device into at least two pieces substantially along an axis aligned with the scored portion. 
     
     
         22 . The method of  claim 18 , wherein the at least one portable asphalt brick device comprise a nanoparticle sensor. 
     
     
         23 . The method of  claim 18 , wherein the at least one portable asphalt brick device is a plurality of portable asphalt brick devices wrapped to facilitate transport by a user. 
     
     
         24 . A method of using a preformed portable asphalt brick device to repair a road deformity, comprising:
 determining the composition of the preformed portable asphalt brick device based on a geographic location of the road deformity;   ordering the preformed portable asphalt brick device;   manufacturing the asphalt brick device by mixing at least an aggregate material and a binding agent;   forming a shape of the preformed portable asphalt brick device;   transporting the preformed portable asphalt brick device to the repair site;   heating the preformed portable asphalt brick device to form a paving repair substance; and   repairing the repair site using the paving repair substance.   
     
     
         25 . The method of  claim 24 , wherein the composition of the preformed portable asphalt brick device is based at least upon the temperature and use properties of the geographic location of the road deformity. 
     
     
         26 . The method of  claim 24 , further comprising adding an additive to the paving repair substance.