Method and system for repairing potholes in roads

Abstract

A system and method for repairing potholes in a road surface by securing a securing device within a pothole, affixing a reinforcing material to the securing device in the pothole, and adding a polyurethane and/or polyisocyanurate foam material to encapsulate the securing device and reinforcing material.

1 . A method for repairing a pothole in a road surface, comprising:
 securing a securing device in said pothole;   affixing a reinforcing material to said securing device within said pothole; and   adding a foam material to said pothole, wherein said foam material encapsulates said securing device and said reinforcing device within said pothole.   
   
   
       2 . The method according to  claim 1 , wherein said securing device comprises one or more securing rods, one or more securing stakes, and/or combinations thereof. 
   
   
       3 . The method according to  claim 1 , wherein said securing device is disposed about the bottom of the pothole and/or in the sidewalls of the pothole. 
   
   
       4 . The method according to  claim 1 , wherein said securing device comprises a material selected from the group consisting of: metal, wood, plastic, and any combinations thereof. 
   
   
       5 . The method according to  claim 1 , wherein said reinforcing material comprises a material selected from the group consisting of: metal, prefabricated metal, plastic, wood, synthetic material, rope, fabric, and any combinations thereof. 
   
   
       6 . The method according to  claim 5 , wherein said reinforcing material is formed in a mesh and/or grid configuration. 
   
   
       7 . The method according to  claim 1 , wherein said foam material is lightweight. 
   
   
       8 . The method according to  claim 1 , wherein said foam material comprises a closed-cell foam. 
   
   
       9 . The method according to  claim 1 , wherein said foam material is selected from the group consisting of polyurethane foam, polyisocyanurate foam, and combinations thereof. 
   
   
       10 . The method according to  claim 9 , wherein said foam material further comprises:
 a blowing agent selected from the group consisting of: water, carbon dioxide, methyl formate, hydrocarbon, hydrochlorofluorocarbon (HCFC), hydrofluorocarbon (HFC), low Global Warming Potential hydrofluorocarbon (low GWP HFC), and any combinations thereof; and   a blowing agent additive selected from the group consisting of: α-methyl styrene, isobutanol, isopropanol, and any combinations thereof,   wherein said blowing agent and said blowing agent additive contact a mixture of ingredients which react to form said polyurethane foam and/or polyisocyanurate foam.   
   
   
       11 . The method according to  claim 10 , wherein said hydrofluorocarbon is selected from the group consisting of: 1,1,1,3,3-pentafluoropropane (HFC-245fa), 1,1,1,2-tetrafluoroethane (HFC-134a), 1,1,2,2-tetrafluoroethane (HFC-134), 1,1,1,3,3-pentafluorobutane (HFC-365mfc), 1,1,1,2,3,3,3-heptafluoropropane (HFC-227ea), and any combinations thereof. 
   
   
       12 . The method according to  claim 10 , wherein said blowing agent additive is present in an amount of from between about 0.02 to about 10 weight percent, based on a total amount of said blowing agent. 
   
   
       13 . The method according to  claim 10 , wherein said blowing agent comprises 1,1,1,3,3-pentafluoropropane (HFC-245fa), and said blowing agent additive comprises α-methyl styrene; and
 wherein said α-methyl styrene is present in an amount of from between about 0.02 to about 10 weight percent, based on a total amount of said 1,1,1,3,3-pentafluoropropane (HFC-245fa).   
   
   
       14 . The method according to  claim 10 , wherein said polyurethane foam and/or polyisocyanurate foam comprises a pre-blended foam formulation, wherein said pre-blended foam formulation comprises:
 a first component that is an “A-side” component; and   a second component that is a “B-side” component,   wherein said blowing agent is incorporated in said first component (“A-side”) and/or said second component (“B-side”), and   wherein said polyurethane foam and/or polyisocyanurate foam are prepared by mixing said first component (“A-side”) and said second component (“B-side”), and placed in the pothole.   
   
   
       15 . The method according to  claim 1 , further comprising:
 placing a surfacing compound on said foam material, said surfacing compound selected from the group consisting of: dirt, paint, asphalt, coating, and any combinations thereof.   
   
   
       16 . A kit for repairing a pothole in a road surface, comprising:
 a securing device;   a reinforcing material; and   a two-container foam dispensing system comprising a first container that contains a first composition, and a second container that contains a second composition, and a dispensing apparatus for each of said first container and said second container,   wherein said first composition and said second composition can be mixed to form a foam material to repair a pothole.   
   
   
       17 . The kit according to  claim 16 , wherein said foam material is selected from the group consisting of: polyurethane foam, polyisocyanurate foam, and combinations thereof. 
   
   
       18 . The kit according to  claim 16 , wherein the dispensing apparatus is a spray nozzle. 
   
   
       19 . The kit according to  claim 16 , further comprising:
 a surfacing compound selected from the group consisting of: dirt, paint, asphalt, coating, and any combinations thereof.