Method of forming an inlaid pattern in an asphalt surface

Abstract

In one embodiment the method comprises the steps of providing a first template having a predetermined pattern; impressing the first template into the asphalt surface when the asphalt surface is in a pliable state to form an impression therein; removing the first template from the asphalt surface to expose the impression; providing a second template having a predetermined pattern matching the pattern of the first template; inserting the second template into the impression; and fixing the second template in position within the impression to form the inlaid pattern. The second template may consist of a preformed thermoplastic grid having a color and/or texture contrasting with the asphalt surface. In another embodiment the second template may include a light source for illuminating the template after it has been fixed in position. A heating method is described for gradually heating large asphalt surfaces using a reciprocating bank of infrared heaters to thermally fix the thermoplastic grid in place.

1 . A method of forming an inlaid pattern in an asphalt surface comprising: 
 (a) providing a first template having a predetermined pattern;    (b) impressing said first template into said asphalt surface when said asphalt surface is in a pliable state to form an impression therein;    (c) removing said first template from said asphalt surface to expose said impression:    (d) providing a second template having a predetermined pattern at least partially matching the pattern of said first template;    (e) inserting said second template into said impression; and    (f) fixing said second template in position within said impression to form said inlaid pattern.    
   
   
       2 . The method as defined in  claim 1 , further comprising the step of heating said asphalt surface prior to impressing said first template into said asphalt surface.  
   
   
       3 . The method as defined in  claim 1 , wherein the step of fixing said second template in position within said impression comprises heating said second template to cause said second template to bond to said asphalt surface.  
   
   
       4 . The method as defined in  claim 3 , wherein said second template is heated to a temperature within the range of approximately 100°-400° F.  
   
   
       5 . The method as defined in  claim 3 , wherein said second template is heated to a temperature within the range of approximately 150°-350° F.  
   
   
       6 . The method as defined in  claim 1 , wherein said second template comprises a pre-formed thermoplastic grid.  
   
   
       7 . The method as defined in  claim 1 , wherein said second template is of unitary construction.  
   
   
       8 . The method as defined in  claim 1 , wherein said second template has a color contrasting with the color of said asphalt.  
   
   
       9 . The method as defined in  claim 1 , wherein said second template comprises a light source for illuminating said second template after said template is fixed in position within said impression.  
   
   
       10 . The method as defined in  claim 1 , wherein said second template is luminescent.  
   
   
       11 . The method as defined in  claim 1 , wherein said second template is flourescent.  
   
   
       12 . The method as defined in  claim 1 , wherein said second template comprises an upper surface, wherein said upper surface is substantially flush with the surface of said asphalt when said second template is fixed in position.  
   
   
       13 . The method as defined in  claim 1 , wherein said second template comprises an upper surface, wherein said upper surface is recessed below the surface of said asphalt when said second template is fixed in position.  
   
   
       14 . The method as defined in  claim 1 , wherein said second template comprises an upper surface, wherein said upper surface projects above the surface of said asphalt when said second template is fixed in position.  
   
   
       15 . The method as defined in  claim 1 , wherein second template comprises a grid formed from a plurality of frame elements, wherein said frame elements have a width less than 12 inches.  
   
   
       16 . The method as defined in  claim 15 , wherein said frame elements have a width between ¼ inch and 2 inches.  
   
   
       17 . A method of forming an inlaid pattern in an asphalt surface comprising: 
 (a) providing a portable heating apparatus having a frame extendable over said asphalt surface and at least one heater movable on said frame;    (b) gradually heating said asphalt surface in situ by moving said heater on said frame over said asphalt surface until said asphalt is in a pliable state;    (c) providing a template having a predetermined pattern;    (d) impressing said template into said asphalt surface when said asphalt surface is in said pliable state; and    (e) fixing said template in position to form said inlaid pattern.    
   
   
       18 . The method of  claim 17  wherein said template is formed from a plastic material.  
   
   
       19 . The method of  claim 18 , wherein said template is formed from a thermoplastic material.  
   
   
       20 . The method of  claim 17 , wherein said template is formed from rubber.  
   
   
       21 . The method as defined in  claim 17 , wherein said second template is of unitary construction.  
   
   
       22 . The method as defined in  claim 17 , wherein said template has a color contrasting with the color of said asphalt.  
   
   
       23 . The method as defined in  claim 17 , wherein said template comprises a light source for illuminating said template after it has been fixed in position within said asphalt surface.  
   
   
       24 . The method as defined in  claim 17 , wherein said template is luminescent.  
   
   
       25 . The method as defined in  claim 17 , wherein said template is flourescent.  
   
   
       26 . The method as defined in  claim 17 , wherein said template comprises an upper surface, wherein said upper surface is substantially flush with the surface of said asphalt when said second template is fixed in position.  
   
   
       27 . The method as defined in  claim 17 , wherein said template comprises an upper surface, wherein said upper surface is recessed below the surface of said asphalt when said template is fixed in position.  
   
   
       28 . The method as defined in  claim 17 , wherein said template comprises an upper surface, wherein said upper surface projects above the surface of said asphalt when said template is fixed in position.  
   
   
       29 . The method as defined in  claim 17 , wherein template comprises a grid formed from a plurality of frame elements, wherein said frame elements have a width less than  12  inches.  
   
   
       30 . The method as defined in  claim 29 , wherein said frame elements have a width between ¼ inch and 4 inches.  
   
   
       31 . (Currently Amended) The method as defined in  claim 30 , wherein said frame elements have a width between ⅜ inch and 2 inches.  
   
   
       32 . The method as defined in  claim 17 , wherein the thickness of said template is between 20-160 mil.  
   
   
       33 . The method as defined in  claim 32 , wherein the thickness of said template is between 40-130 mil.  
   
   
       34 . The method as described in  claim 1 , further comprising coating said asphalt surface with a clear sealant after said second template is fixed in position.  
   
   
       35 . A method of forming an inlaid pattern in an asphalt surface comprising: 
 (a) gradually heating said asphalt surface in situ until it is in a pliable state by repeatedly passing an infrared heater thereover;    (b) forming an impression in said asphalt surface;    (c) introducing a settable material into said impression; and    (d) allowing said settable material to set within said impression to form said inlaid pattern.    
   
   
       36 . The method as defined in  claim 35 , wherein said settable material is permanently fixed within said impression.  
   
   
       37 . The method as defined in  claim 35 , wherein said settable material is thermoplastic.  
   
   
       38 . The method as defined in  claim 36 , further comprising providing a template having a predetermined pattern and wherein the step of introducing a settable material into said narrow impression comprises placing said template into said impression.  
   
   
       39 . The method as defined in  claim 35 , wherein said impression is between ¼ inch and 4 inches in width.  
   
   
       40 . (Currently Amended) The method as defined in  claim 35 , wherein said inlaid pattern is decorative.  
   
   
       41 . A template suitable for impression into a pliable asphalt surface comprising a thermoplastic grid formed from a plurality of frame elements defining a plurality of open areas therebetween, wherein each of said frame elements has a width less than  4  inches and wherein said open areas comprise approximately 50-90% of the total surface area of said template.  
   
   
       42 . The template as defined in  claim 41 , wherein said frame elements have a width between ⅜ inch and 2 inches.  
   
   
       43 . The template as defined in  claim 42 , wherein the thickness of said template is between 20-160 mil.  
   
   
       44 . The template as defined in  claim 43 , wherein the thickness of said template is between 40-130 mil.  
   
   
       45 . The template as defined in  claim 41 , wherein said template is formed from a material selected from the group consisting of a flourescent material, a luminescent material and a luminous material.  
   
   
       46 . A method of forming an inlaid pattern in an asphalt surface comprising: 
 (a) forming an impression in said asphalt surface;    (b) placing a thermoplastic template into said impression; and    (c) gradually heating said thermoplastic template by periodically passing at least one heater thereover until said template adheres to said asphalt surface.    
   
   
       47 . The method as defined in  claim 46 , wherein said impression is formed in said asphalt surface when said asphalt surface is in a pliable state.  
   
   
       48 . The method as defined in  claim 46 , wherein said heater is an infrared heater.  
   
   
       49 . The method as defined in  claim 48 , wherein said asphalt surface is allowed to partially cool after each successive pass of said infrared heater.  
   
   
       50 . The method as defined in  claim 49 , wherein said infrared heater is supported from a rail extending above said asphalt surface, wherein said heater reciprocates on said rail between first and second positions.  
   
   
       51 . The method as defined in  claim 50 , wherein the surface area covered by said template and traversed by said heater exceeds approximately 10 square feet.  
   
   
       52 . The method as defined in  claim 2 , wherein said asphalt surface is heated in situ.  
   
   
       53 . The method as defined in  claim 16 , wherein said template comprises a plurality of frame elements defining a plurality of open areas therebetween, wherein said open areas comprise approximately 50-90 % of the total surface area of said template.