WO2024220893A1 - Stretchable silicone mold for molten asphalt material - Google Patents

Abstract

A method for rapidly solidifying objects or materials containing molten asphalt by providing the molten asphalt into a container made from a silicone polymer material, and contacting the molten asphalt with a cooling operation such as cryogenic liquid or gas cooling, noncryogenic cooling, or ambient air cooling. In a manufacturing facility for making blocks of asphalt-containing material, less time and floor space are needed for cooling the blocks. At a job site, remelted asphalt-containing objects or materials can be used for purposes including sealing joints and cracks in pavement surfaces such as cement and asphalt, repairing roofs, or repairing or making pavement, and cryogenic liquified nonflammable gas or another cooling operation may be applied at the job site to rapidly resolidify the asphalt.

Description

STRETCHABLE SILICONE MOLD FOR MOLTEN ASPHALT MATERIAL

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/460,520 filed April 19, 2023, the disclosure of which is incorporated herein in its entirety.

TECHNICAL FIELD

[0002] The present disclosure is generally related to petroleum-derived products stored in a container. More specifically, the present disclosure relates to a stretchable silicone mold configured to shape and solidify molten asphalt sealant materials, such as an amorphous asphalt-containing material, for storage or transportation.

BACKGROUND

[0003] Sealants are used for sealing joints and cracks in concrete and asphaltic pavements and parking lots. It is known in the art to deliver packaged blocks of sealant material to a job site, which are then melted in a kettle on-site. The melted sealant can be used to seal joints or fill cracks in the pavement. It is also known in the art to use a material for the packaging which can become incorporated into the molten sealant product. For example, U.S. Pat. No. 8,017,681 to Guymon et al. describes adding a thermoplastic product to a foamed polymer container, the foamed polymer container being an ingredient in the sealant product such that the entire container and its contents can be placed in a kettle on the job site and melted. Also known is the use of less-bulky polyolefin film (e.g., polypropylene film) as packaging, as described for example in U.S. Pat. No. 5,452,800 to Muir, for use with roofing asphalt applications, and in U.S. Pat. No. 9,637,252 to Splinter et al., for use with asphalt sealant blocks. Muir uses a water trough for cooling molds containing its molten roofing asphalt product, and Splinter et al. uses a water bath for initial cooling of pans containing its asphalt sealant product followed by placing the pans in a wind tunnel.

[0004] As described, for example, in Guymon et al. and U.S. Pat. No. 6,230,890 to Waver et al., the use of silicone coated paper containers for cooling and containing asphalt materials is also known in the art. Guymon et al. further describes a process of including ingredients for a thermoplastic product in a container for storage or transportation, where the container is an ingredient of the final thermoplastic product (e.g., the container and the ingredients are melted together to form the final thermoplastic product). The container described by Guymon et al. is therefore not reusable after a single instance of creating (e.g., molding) the thermoplastic product. Waver et al. describes using silicone paper positioned between layers of hot melt adhesive masses. The silicone paper prevents adhesion of the masses to one another.

[0005] PCT Application No. 2004/078448 to Petry et al. describes a method for producing a package made of thermoplastic material using a casting mold made of a silicone elastomer. Petry et al. is specifically directed to thermoplastic materials having a crystalline to waxy or gummy consistency at room temperature (e.g., the materials have a crystalline lattice structure rather than an amorphous structure).

[0006] Improvements are needed for producing packages or containers of amorphous asphalt-containing materials for use in the construction and repair of pavement and roofing. The present disclosure addresses these concerns.

SUMMARY OF THE DISCLOSURE

[0007] Silicone polymers may be used to form containers that are stretchable, reusable, and have low surface energy for shaping, cooling, and removal of molten asphalt products without damaging the container.

[0008] The present disclosure relates to improved techniques for packaging molten asphalt-containing products such as sealants, roofing asphalts and coatings. In one aspect, the present disclosure provides a method for forming packaged solidified shaped objects (e.g., blocks, cylinders, tablets or other shapes) made from an amorphous molten asphalt and optional additional ingredients, wherein the asphalt is cooled from a molten to solid state by exposing the molten asphalt to cryogenic liquified nonflammable gas (viz., as a liquid or as the cryogenic vapors thereof). Alternatively, the asphalt can be cooled from a molten to solid state by exposing the molten asphalt to ambient air or non-cryogenic cooling operations (e.g., a nonflammable liquid). Ambient air cooling takes longer than rapid cryogenic cooling but achieves the same outcome of forming a hardened sealant block.

[0009] Either cooling approach can significantly reduce the manufacturing footprint (e.g., the floor space and time) required for asphalt solidification. For example, a molten asphaltcontaining material may be quickly solidified by spraying or dousing the asphalt material with a cryogenic liquified nonflammable gas such as liquid nitrogen (“LN2”) or liquid carbon dioxide (“LCO2”), submerging the material in a bath of liquified nonflammable gas, conveying the material through a liquified nonflammable gas-chilled tunnel freezer or a spiral freezer like those used to flash-freeze frozen pizzas prior to distribution, or cooling the material using ambient air or non-cryogenic cooling operations (e.g., liquid cooling). These solidification procedures may for example be performed indoors, e.g., inside a manufacturing facility.

[0010] In embodiments, the disclosed solidified shaped objects may be at least partially enveloped by a sheet of packaging film (e.g., thermoplastic material such as polypropylene film) to form a self-sealed package of one or more shaped objects that can be added to and melted in a heated kettle at a job site. The packaging film acts as an inexpensive, easily stored container that can be melted into the kettle contents at the job site.

[0011] Other objects, advantages, features, properties and relationships of the disclosure will be obtained from the following detailed description and accompanying drawings which set forth illustrative embodiments that are indicative of the various ways in which the principles of the disclosure may be employed.

BRIEF DESCRIPTION OF THE DRAWING

[0012] FIG. l is a top perspective view of a container for receiving a volume of asphaltcontaining material;

[0013] FIG. 2A is a top perspective view of the container of FIG. 1 half-full of an asphalt-containing material placed therein;

[0014] FIG. 2B is a top perspective view of the container of FIG. 1 full of an asphaltcontaining material placed therein;

[0015] FIG. 3 is a side view, partially in phantom, of a cryogenic cooling machine used to rapidly solidify blocks of asphalt-containing material;

[0016] FIG. 4 is a top perspective view of a block of cooled material removed from the container of FIGS. 1, 2 A, and 2B;

[0017] FIG. 5 is a top perspective view of three blocks of cooled material stacked together;

[0018] FIG. 6 is a conceptual diagram showing the three blocks of cooled material of FIG. 5, both before and after being stacked together; [0019] FIG. 7 is a top perspective view of the three stacked blocks of cooled material of FIGS. 5 and 6 wrapped in a film;

[0020] FIG. 8 is a flowchart illustrating a method of packaging an asphalt-containing product in a container made from a silicone polymer;

DETAILED DESCRIPTION

[0021] The recitation of a numerical range using endpoints includes all numbers subsumed within that range (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0022] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably. Thus, for example, a sealant composition that contains “an” additive means that the composition includes “one or more” additives.

[0023] The term “aggregate” refers to particulate mineral material such as limestone, granite, trap rock, gravel, crushed gravel sand, crushed stone, crushed rock and slag useful in paving and pavement applications.

[0024] The term “ambient air” generally refers to the definition provided in 40 C.F.R. § 50.1, namely the “portion of the atmosphere, external to buildings, to which the general public has access.” Ambient air may also refer to air internal to buildings, for example when ambient air is used for cooling operations inside a manufacturing facility. Ambient air is one example of a non-cryogenic cooling operation.

[0025] The term “amorphous” refers to a material that has no internal crystalline structure. Asphalt is one example of an amorphous material.

[0026] The term “asphalt” (also referred to in some jurisdictions as “bitumen”) refers to a class of black or dark-colored (solid, semisolid, or viscous) cementitious substances, natural or manufactured, composed principally of high molecular weight hydrocarbons, and typically including components such as saturates, aromatics, resins and asphaltenes. “Asphalt” as used herein may also refer to “asphalt-containing material.”

[0027] The term “asphalt binder” refers to a material including bitumen and optionally other components that is suitable for mixing with aggregate to make a paving mix.

[0028] The terms “asphalt paving mixture” or “asphalt mix” or “mix” refer to an uncompacted mixture of asphalt and aggregate. Depending on local usage, the terms “bitumen mix” or “bituminous mixture” may be used interchangeably with or in place of the terms “asphalt paving mixture” or “asphalt mix” or “mix.” [0029] The term “asphalt sealant” refers to an asphalt-containing material that can be used to fill cracks or gaps in a surface or structure.

[0030] The term “cryogenic” when used in connection with a gas, means that the gas has an atmospheric pressure boiling point less than -50°C (-58°F).

[0031] The term “elastomer” refers to its definition in ASTM DI 566 as a “macromolecular material that returns rapidly to approximately the initial dimensions and shape after substantial deformation by a weak stress and release of the stress.” An “elastomeric material” is a material having the properties of an elastomer as provided by ASTM D1566.

[0032] The term “liquified” when used in connection with a substance that is normally a gas at atmospheric pressure, means that the substance has been stored at a pressure and temperature sufficient for the substance to be in liquid form.

[0033] The term “nonflammable” when used in connection with a liquified gas means that the gas is not easily ignitable. Examples of flammable gases include liquid propane, liquified natural gas, and liquid hydrogen.

[0034] The term “reusable” refers to materials that are capable of repeated use over a period of time without exhibiting any significant degradation warranting removal from use. [0035] The term “stretchable” refers to materials that can be stretched out, extended, elongated, or lengthened upon application of a force or stress against the materials. A stretchable material may comprise an elastomeric material (e.g., silicone) or a non- elastomeric material (e.g., nylon).

[0036] The present disclosure describes exemplary techniques for rapidly cooling molded products and materials containing molten asphalt (e.g., an asphalt sealant product, asphaltcontaining material, or asphalt-containing coating) using a cryogenic liquified nonflammable gas (or in the interest of brevity, a “cryogenic gas”). The present disclosure further describes exemplary techniques for cooling products and materials containing molten asphalt using ambient air or non-cryogenic cooling operations (e.g., liquid cooling). Exemplary such gases for cryogenic cooling include elemental gases (e.g., nitrogen, helium and argon), molecular gases (e.g., carbon dioxide and nitrous oxide), and mixtures of gases. Preferred cryogenic gases are nontoxic (for example, a gas other than ammonia). In addition, preferred cryogenic gases do not support combustion (for example, a gas other than liquid oxygen or liquified nitrous oxide). [0037] FIG. 1 shows a generally rectangular container 10 configured to receive a volume of asphalt-containing material, as detailed further below. In embodiments, container 10 may have a thickness of about 25 mm to about 127 mm (about 1 inch to about 5 inches), a width of about 25 cm to about 51 cm (about 10 inches to about 20 inches), and a length of about 38 cm to about 76 cm (about 15 inches to about 30 inches). Exemplary dimensions of container 10 are 76 mm by 36 cm by 56 cm (3 inches by 14 inches by 22 inches), although other dimensions are contemplated, and a container of any suitable dimensions (and shapes) may be used. Container 10 will generally have rounded corner edges to avoid stress concentration points in the corner locations. Container 10 can be manufactured using a molding process, a subtractive manufacturing process, or an additive manufacturing process, depending on necessary material tolerances and properties.

[0038] Container 10 can comprise a stretchable, reusable silicone polymer (e.g, a silicone-containing material) in the form of a silicone mold. Silicone is a stretchable material with low surface energy properties advantageous for the examples provided herein. For example, the flexibility of silicone materials can enhance the durability of container 10 as compared to similar containers made from metal. Silicone materials are also resistant to bonding or sticking to non-silicone materials because silicone typically bonds only to itself. Accordingly, container 10 made from a stretchable, reusable silicone polymer does not need to be lined or draped with a polymer sheet before molten asphalt-containing material is poured, as it would if container 10 was made from metal. The elimination of such polymer sheets advantageously reduces material costs and saves time during the operations described herein. In embodiments, container 10 can be made from an elastomeric silicone polymer. In embodiments, container 10 can be made from non-elastomeric materials such as nylon.

[0039] As shown in FIGS. 2A and 2B, a molten (e.g, hot, liquid) sealant material 14 is poured within container 10. FIG. 2A illustrates container 10 half-full of sealant material 14 (e.g., an asphalt-containing material), whereas FIG. 2B illustrates container 10 full of sealant material 14 (e.g., completely full or substantially full). Sealant material 14 may comprise any suitable composition appropriate for filling or coating cracks and joints in concrete and asphaltic pavements or roofs. One example of a suitable sealant material 14 is a composition of asphalt binder, petroleum oil, a thermoplastic polymer, and limestone, although other suitable sealant materials are contemplated and may be used. In embodiments, sealant material 14 may comprise an amorphous asphalt-containing material. [0040] After container 10 is filled with molten sealant material 14, container 10 and sealant 14 can be actively cooled with a cryogenic gas to harden sealant 14 into a solid state, which generally occurs at or below about 49°-54°C (120°-130°F). Alternatively, container 10 and sealant 14 can be actively cooled using a non-cryogenic cooling operation (e.g., general freezer cooling, liquid cooling) or passively cooled using ambient air. In embodiments, container 10 may initially be placed onto a conveyor, such as a steel belt, which travels through a water bath for a preliminary round of cooling. In some such embodiments, a chiller may be used to maintain the water at a sufficiently cold temperature. [0041] In accordance with techniques of this disclosure, filled container 10 can undergo rapid cooling by contacting sealant 14 (e.g., the top surface of sealant 14) with the liquified or vaporized form of a cryogenic gas, such as liquid nitrogen (“LN2”) or liquid carbon dioxide (“LCO2”), if cryogenic cooling is used. For instance, in the embodiment shown in FIG. 3, filled pans 10 are fed into a cryogenic freezer 16, such as a “tunnel freezer” or “spiral freezer,” of the kind typically used to flash-freeze frozen pizzas for mass-distribution. Nonlimiting examples of such cryogenic freezers are the Cryoline® CryoVantage Tunnel Freezer and the Cryoline® Ultra-Performance Spiral Freezer, both available from Linde pic of Dublin, Ireland. Using a cryogenic gas to rapidly cool a product or article containing molten asphalt allows the cooling process to be completed in a matter of minutes (e.g., on the order of 30 minutes or less, depending on factors including the initial pour temperature, container size, ambient conditions, production rate, presence of nearby heat sources or heat sinks, and so on), rather than taking several hours or even several days using standard cooling techniques. In fact, it is estimated that for the manufacture of asphalt sealant blocks, eliminating this current bottleneck in sealant block packaging, the manufacturing footprint (e.g., the amount of time and factory-floor space) required to manufacture each sealant block may slashed by up to one-half or even more, or alternatively may enable the packaged sealant block production rate to be doubled or even more than doubled. Sealant block manufacturing facilities that implement this new rapid-cooling technique will typically be located indoors, and the associated cryogenic storage container, such as an LN2 tank, will typically be located above ground outside the manufacturing facility.

[0042] Alternatively, the filled container is cooled and hardened using non-cryogenic cooling operations or ambient air cooling. While such cooling operations take longer than cryogenic cooling, the same outcome of forming a hardened sealant block is achieved with this approach. Moreover, because container 10 is made from a silicone material, cooling with non-cryogenic or ambient air operations does not limit the flexibility and advantageous bonding properties of the container 10. Either cooling approach achieves the benefit of not requiring a separate polymer sheet lined or draped within container 10 before molten asphalt is poured therein. The poured amorphous asphalt-containing material can harden and then be removed without damaging container 10 because of its low surface energy because of being made from a silicone material. Container 10 may then be reused in subsequent pouring and cooling operations for an extended period of time.

[0043] As shown in FIG. 4, once sealant material 14 has been cooled to a solid state, a solid block 18 is produced. In embodiments, the rate of cooling and composition of the sealant are such that the cooled and solidified block 18 is crack-free. In other embodiments, the rate of cooling and composition of the sealant are such that the cooled and solidified block 18 includes cracks. The inclusion of cracks in the solidified sealant product may be desirable to speed the rate of remelting when block 18 is remelted in a kettle at a job site. [0044] Further disclosure of cryogenic cooling of asphalt-containing materials is provided in U.S. Provisional Patent Application No. 63/460,520 and a co-pending PCT Application filed even date herewith under Attorney Docket No. 569079-36, the disclosures of which are incorporated herein in their entireties.

[0045] As shown in FIGS. 5 and 6, block 18 may be wrapped in a sealing film 12 comprised of a material that, when heated past its melting point, mixes with block 18 to become part of an end sealant product. Sealing film 12 ensures a complete seal around block 18 for storage or transport. Sealing film 12 may be tightly wrapped around block 18 (e.g., film 12 and block 18 are in direct contact), or loosely wrapped around block 18 to from a small air gap in the area between film 12 and block 18. In embodiments, block 18 may be wrapped in sealing film 12 manually by an operator, semi-automatically using a combination of an operator and a machine, or automatically using a machine (e.g., shrink-wrap machine). [0046] Multiple covered sealant blocks 18A-18C may be placed together to form a selfsealed package 22 of two or more sealant blocks 18. In embodiments, container 10 (FIGS. 1, 2A, and 2B) is sized to create finished sealant blocks 18 weighing approximately 4.5 Kg (10 lbs.). In some such embodiments, three individual sealant blocks 18A-18C may then be selfsealed together to produce an approximately 13.6 Kg (30 lb.) package 22, which permits easy handling and allows the entire package 22 to fit into a melting kettle for use at a job site. Container 10 can alternatively be sized to produce sealant blocks 18 of varying sizes, as well as packages 22 comprised of varying numbers of sealant blocks 18 and having varying total weights.

[0047] As shown in FIG. 6, to create package 22, two or more wrapped sealant blocks 18A, 18B, and 18C are stacked together, with the at-least-partially uncovered surfaces 20A, 20B, of two blocks 18A, 18B, respectively, placed adjacent to (viz., facing) one another, and the at least partially uncovered surface 20C of any additional blocks 18C placed on the bottom of the stack of two, forming a package 22 of two or more blocks 18A-18C.

[0048] As shown in FIG. 7, package 22 can optionally be further wrapped in an outer wrapping film 24 comprised of a material that, when heated past its melting point, mixes with sealant material 14 to become part of the end sealant product. Outer film 24 ensures a complete seal around package 22 for transport. In embodiments, self-sealed package 22 is placed on a pallet (not shown in FIG. 7) and wrapped using a shrink-wrap machine with a suitable film 24. Using a shrink-wrap version of film 24 helps give the pallet stability and weather-proofs the sealant.

[0049] FIG. 8 is a flowchart 26 illustrating a method of forming and packaging a sealant product made from a hot, molten sealant material (e.g., an amorphous asphalt-containing material), as shown and described above with respect to FIGS. 1-7. The method includes providing a container made from a stretchable, reusable silicone polymer that is configured to receive a hot, molten sealant material 14 (28). Sealant material 14 may be an amorphous asphalt-containing material in embodiments. The method further includes pouring a hot, molten sealant material 14 within container 10 made from a silicone material (30). As described above, filled container 10 can be fed through a cryogenic cooling machine 16, such as a tunnel cooler or a spiral cooler, configured to bombard molten sealant 14 with a cryogenic gas, such as LN2 or LCO2 (32), causing sealant 14 to rapidly harden into a solid block 18. Alternatively, filled container 10 can be actively cooled and hardened using a noncry ogenic cooling operation (e.g., liquid cooling) or passively cooled and hardened using ambient air (32).

[0050] Solid block 18 (e.g., hardened sealant material 14) can be removed from container 10 (34) and stacked with one or more additional blocks to form a sealed package 22 (36). Because container 10 is made from a stretchable and reusable silicone polymer material having low surface areas, block 18 can be easily removed from container 10 without causing damage or degradation to the container 10. Optionally, package 22 can be wrapped in an outer wrapping film 24, such as shrink-wrap, to ensure retention of the blocks (38). Once sufficiently sealed, packages 22 may be transported to a job site (40) and placed into a kettle (42).

[0051] As described above, where a sealant block 18 is dimensioned to weigh approximately 4.5 Kg (10 lbs.), three individual sealant blocks 18 may be stacked together to form a three-block package 22 weighing approximately 13.6 Kg (30 lbs.). Packages 22 of this approximate size and weight fit into standard-sized melting kettles, and also allow for easy lifting of packages 22 from pallets or other methods or devices for transporting packages 22 into melting kettles on site. However, also consistent with this disclosure are individual sealant blocks 18 formed in pans 10 with varying dimensions to result in sealant blocks 18 with varying sizes and weights. For example, two sealant blocks 18 of approximately 6.8 Kg (15 lbs.) each, or any other suitable combination of block number and weight, may be joined to form an approximately 13.6 Kg (30 lb.) package 22.

[0052] The job site kettle typically is heated until sealant material 14 and film 24 (if present) melt and mix together, forming a liquid sealant (44). Simultaneously melting multiple smaller blocks 18 in the melting kettle has the key advantage of allowing sealant blocks 18 of package 22 to melt faster and more evenly than systems using use one large sealant block. For instance, when package 22 is placed into an oil-jacketed melting kettle and heated to approximately 188°C (370°F), film 24 and sealant material 14 melt to form the final liquid sealant product. As sealant material 14 begins to melt, package 22 separates. Molten sealant migrates into the spaces between individual sealant blocks 18 and accelerates the melting process. This allows a greater surface area of still-solid sealant material 14 to be exposed to hot liquid sealant more quickly, allowing package 22 to melt approximately two- and-a-half-times faster than traditional systems that use just one large block of sealant material. The use of multiple, smaller blocks 18 as opposed to one large block of material also allows blocks 18 to melt more evenly than melting one large block of material.

[0053] The liquid sealant may be applied to joint or crack in, for example, a roofing or pavement surface (46), followed by applying a cooling operation (e.g., cryogenic gas, cooling liquid such as water, or ambient air cooling) to the applied liquid sealant to cool and harden the sealant (48). Repair of roofing, pavement, and other structures is thereby achieved using the method illustrated in flowchart 26. [0054] While specific embodiments of the disclosure have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the disclosure, which is to be given the full breadth of the appended claims and any functional equivalents thereof.

Claims

CLAIMS What is claimed is:

1. A method comprising the steps of: providing a reusable, stretchable container made from a silicone polymer; placing a molten volume of an amorphous asphalt-containing material into the container; applying a cooling operation to the asphalt-containing material within the container to cool and solidify the material, thereby forming a molded block comprising the material; and removing the block from the container.

2. The method of claim 1, wherein the silicone polymer has a low surface energy such that the block can be removed without damaging the block or the container.

3. The method of claim 1, wherein the silicone polymer is elastomeric.

4. The method of claim 1, wherein the cooling operation is a cryogenic liquified nonflammable gas.

5. The method of claim 1, wherein the cooling operation is a non-cryogenic cooling operation.

6. The method of claim 5, wherein the non-cryogenic cooling operation is nonflammable liquid cooling.

7. The method of claim 1, wherein the cooling operation is ambient air cooling.

8. The method of claim 1, wherein the asphalt-containing material comprises asphalt binder.

9. The method of claim 1, wherein the asphalt-containing material comprises asphalt, oil, a thermoplastic polymer, and limestone.

10. The method of claim 1, wherein the asphalt-containing material comprises asphalt paving mixture.

11. The method of claim 1, wherein the asphalt-containing material comprises asphalt and aggregate.

12. The method of claim 1, wherein applying the cooling operation to the asphaltcontaining material comprises feeding the container through a cryogenic freezer.

13. The method of claim 12, wherein the cryogenic freezer comprises a tunnel freezer.

14. The method of claim 13, wherein the cryogenic freezer comprises a spiral freezer.

15. The method of claim 1, wherein applying the cooling operation to the asphaltcontaining material comprises spraying the sealant material with cryogenic liquid or gas.

16. The method of claim 1, wherein applying the cooling operation to the asphaltcontaining material comprises submerging the sealant material in a bath of cryogenic liquid or gas.

17. The method of claim 1, wherein the cooling operation is applied to the asphaltcontaining material at a rate sufficient to harden the material without cracking the solidified block.

18. The method of claim 1, wherein the cooling operation is applied to the asphaltcontaining material at a rate sufficient to harden the material and form one or more cracks in the solidified block.

19. The method of any one of the preceding claims, wherein the cooling operation is nontoxic.

20. The method of any one of the preceding claims, wherein the cooling operation does not support combustion.

21. The method of any one of claims 1-20, wherein the cooling operation comprises liquid nitrogen gas.

22. The method of any one of claims 1-20, wherein the cooling operation comprises liquid carbon dioxide gas.

23. The method of any one of the preceding claims, wherein solidification of the asphaltcontaining material takes place in ten minutes or less.

24. The method of any one of the preceding claims, further comprising placing the block in a heated kettle to form a remelted liquid sealant, and applying the liquid sealant to a joint or a crack in a surface comprising concrete, asphalt or pavement.

25. The method of claim 24, further comprising applying a cryogenic cooling operation to the liquid sealant to rapidly resolidify the liquid sealant.

26. The method of any one of the preceding claims, wherein the container has a rectangular geometry.

27. The method of claim 26, wherein the container has a thickness of about 25 mm to about 127 mm, a width of about 25 cm to about 51 cm, and a length of about 38 cm to about 76 cm.

28. The method of claim 27, wherein the container has a thickness of about 76 mm, a width of about 36 cm, and a length of about 56 cm.

29. The method of claim 1, wherein the container is cooled before the step of placing a molten volume of the asphalt-containing material into the container.