Method of forming an inlaid pattern in an asphalt surface
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.