Method of forming an inlaid pattern in an asphalt surface

• US 20050089372A1
• Filed: 12/03/2002
• Published: 04/28/2005
• Est. Priority Date: 12/04/2001
• Status: Abandoned Application

• Current Assignee: Integrated Paving Concepts Inc.
• Original Assignee: Integrated Paving Concepts Inc.
• Inventors: Wiley, Patrick Carl
• Application Number:
  US10/497,354
• Publication Number:
  US 20050089372A1
• Time in Patent Office: Days
• US Class Current: 404/75
• CPC Class Codes: E01C 19/43 Machines or arrangements for roughening or patterning freshly-laid paving courses, e.g. indenting rollers
• CPC Class Codes: E01C 23/028 Positioning or producing markings, e.g. by forcing marking materials into the surface, by scoring
• CPC Class Codes: E01C 23/14 for heating or drying foundation, paving, or materials thereon, e.g. paint E01C23/03 takes precedence; heating or drying devices incorporated in the paving E01C11/26; surface soil stabilisation by fusing, calcining or burning soil in situ E01C21/02; for street cleaning E01H1/08; melting snow or ice on surfacing E01H5/10

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.

Claims

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.

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.

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.

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.

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.