The following application is a continuation of and claims benefit of US Design Patent Application numbers 29/523,028 filed on April 6, 2015 and US Design Application 29/523, 031 also filed on April 6, 2015. This application is also a continuation of and claims priority to US nonprovisional patent application number 12/592,462, filed November 25, 2009 and entitled, "Pavement Marking Pattern and Method".

TECHNICAL FIELD

The present invention relates to a method of forming multiple patterns onto a pavement surface from a single thermoplastic patterned preform that includes four independent and distinct sections that taken together (collectively) comprise a simulated groutless paver or paver-like pattern. The groutless pattern is selected for functional and decorative purposes in lieu of using conventional pavers.

BACKGROUND

Various methods for forming patterns on paved surfaces are known in the related art. The Applicant is the owner of U.S. Pat. No. 8,864,409 describing a method of forming multiple inlaid patterns to complete a final predetermined rotational pattern onto or into a pavement surface. This pattern is provided by a method including the steps of providing a first template created of multiple blocks with portions of rotational isometric patterns having a

predetermined pattern; impressing the first template into the pavement surface when the pavement surface is in a pliable state forming an impression followed by removing the first template from the pavement surface and exposing the impression; providing a grid having a predetermined pattern matching the pattern of the first template; inserting the grid into the impression; and fixing the grid in position within the impression to form the inlaid pattern thereby creating multiple blocks with grout sections separating these patterns or portions of these patterns. Applicant is also the owner of U.S. Pat. No. 5,215,402, which describes a method of forming a pattern in an asphalt surface using a removable template. This template is compressed into a pliable asphalt surface to imprint a predetermined pattern simulating, for example, the appearance of bricks, cobblestones, interlocking paving stones or the like. The template is then lifted clear of the asphalt surface and the asphalt is allowed to harden. A thin layer of a cementitious coating may be applied to the imprinted asphalt to enhance the brick and mortar or other desired effect. This pattern includes the use of grout or grout-like sections that separate the interlocking bricks, cobblestones, and interlocking paving stones. In the above-described method the template does not remain inlaid within the asphalt surface. The visual effect is created by the combination of the imprinted pattern and the decorative coating. One important and distinctive drawback to this method and the finished product is that the decorative coating may wear off over time, particularly in high traffic areas.

It also known that it is possible to install traffic markings on asphalt surfaces. However, such markings typically extend and project above the asphalt surface and are relatively bulky. In regions receiving frequent snowfalls during the winter months, traffic markings may often be removed or damaged during snowplow usage. In fact, these patented inventions teach away from the present disclosure in that the use of grout regions for a "paver" patterned preform thermoplastic products are in opposition with the features of that of the present disclosure.

A useful description of a paver pattern is as follows; a number of paving-stones, tiles, bricks, or brick-like pieces of concrete commonly used as exterior flooring. In a factory, concrete pavers are made by pouring a mixture of concrete and optionally some type of coloring agent into a mold of some shape and allowing it to set. They are applied by pouring a standard concrete foundation, spreading sand on top, and then laying the pavers in the desired pattern. Ancient pavers were simply stones or bricks manually inserted into the ground and formed many of the roadways found in ancient Greece and Rome. Many paver type roadways are still found in Europe as well as older North American cities in the United States including Boston and New York. No actual adhesive or retaining method is used other than the weight of the paver itself with the exception of edging. Pavers can be used to make roads, driveways, patios, walkways and other outdoor platforms. Another method for producing similar types of paver traffic markings involves grinding grooves in pavement surfaces and then pouring into these grooves a hot molten material which is allowed to set in place causing an intentional displacement between the grooves and the paver stones, tines, bricks, etc.

However, this is a very time consuming procedure, and is not well suited for forming complicated patterns, or covering large surface areas. The need therefore exists and remains for improved materials and methods to provide groutless patterns on paved surfaces which simulate pavers but are less labor intensive, less costly, quicker to install, and also provide a safer and smoother surface than the heretofore conventional alternatives.

SUMMARY OF INVENTION The present disclosure involves one or more distinct thermoplastic pavement marking patterned preforms comprising at least four independent sections wherein each of the four independent sections are placed on a pavement surface as one complete sheet such that the four independent sections are separate and distinct and the four sections have top surfaces that are coplanar and are also different from one another wherein the difference is selected from the group consisting of: different shades, different colors, and different textures, and wherein at least two of the four independent sections that are contiguous with each other are different shades, colors, or textures and wherein grout lines are non-existent in separating any of the four independent sections that combined together comprise the patterned preforms. In addition, the patterns are paver patterns and/or exhibit paver-like appearances that simulate conventional paver installations. The patterns are provided to simulate one or more brick pavers on a pavement surface with different colored brick patterned sections that fit together so as to obviate grout lines and also obviate inserted inlaid grout features. The trip hazards due to grout lines and non-coplanar portions of the preforms associated with conventional brick pavers are reduced or eliminated. In this case, the preforms are neither picked up nor removed in the presence of traffic or the use of plows over the surface of these unique preforms.

Further, the preforms are of a uniform thickness across the patterns and are of a uniform height across the patterned top surface thereby eliminating roughness, friction, and or vibrations caused when a vehicle or pedestrian crosses over the patterned top surface. The preforms are adhesively applied to the pavement surface.

The adhesively applied preforms are 2x2 sheets each having at least one complete set of 4 independent sections.

In addition, the one or more distinct thermoplastic pavement marking patterned preforms have top, bottom, left and right edges that are in alignment to ensure that brick colors on one preformed patterned sheet will match the colors on a second and subsequent preformed patterned sheet and the sheets are sequentially positioned such that full brick or other patterns of the preforms provide a continuous and contiguous pattern with said top, bottom, left, and right edges.

The preforms comprise four independent sections to form an intersection therebetween and include an adhesive, wherein said adhesive bridges said intersection to maintain marking pattern integrity. The adhesive is either a thermosetting or thermoplastic adhesive and can be sprayable.

The one or more distinct thermoplastic pavement marking patterned preforms comprises a first independent thermoplastic section, a second independent thermoplastic section, a third independent section and a fourth independent section contiguous to each other so as to form an intersection therebetween with a sprayed thermoplastic adhesive, said sprayed thermoplastic adhesive bridging said intersection and adhered to first, second, third, and fourth sections in order to maintain pattern integrity.

In a further embodiment, the present disclosure includes a method of making a pre-bonded preformed thermoplastic patterned sheet comprising: providing a first, second, third, and fourth independent thermoplastic section manufactured as a preformed thermoplastic patterned sheet section that is laid onto a pavement surface wherein the patterned sheet section maintains a coplanar top surface that is patterned to simulate a paver or paver-like top surface. The patterned sheet section comprises a top surface and a bottom surface, such that the patterned sheet section is in direct contact with a paved surface. The method further comprises applying an adhesive backing layer on the bottom surface wherein the adhesive backing layer is bridging and bonding the intersection of the patterned sheet section and the paved surface to form a unified pavement paver or paver-like pattern. This patterned preform thereby prevents dislodging or separation of the preformed thermoplastic patterned sheet during handling, movement, transportation, and application.

The method allows for use on paved surfaces that are asphalt and concrete. The method further comprises the step of heating the asphalt prior to application of the adhesively backed preformed thermoplastic patterned sheet section onto the asphalt.

It is also possible to include the step of fixing the preformed thermoplastic patterned sheet in position with the paved surface by heating the patterned sheet section after application of the patterned sheet section onto the paved surface to cause the patterned sheet section to bond to the paved surface.

The preformed thermoplastic patterned sheet is heated to a temperature within the range of approximately 100 to 400 degrees Fahrenheit, and more preferably in the range of approximately 150 to 350 degrees Fahrenheit. The patterned sheet comprises a pre-formed thermoplastic pattern that is of unitary construction and has colors contrasting with the color of the paved surface. In a further embodiment, the patterned sheet section comprises retroflective elements including glass beads and skid resistant elements that provide the patterned sheet section retroflective capabilities after the patterned sheet section is fixed in position on the paved surface. The patterned sheet section can also be luminescent and/or fluorescent. Additionally, the patterned sheet section comprises an upper surface and a lower surface, wherein the upper surface is substantially flush with the surface of the pavement surface when the patterned sheet is fixed in position.

The predetermined pattern is decorative and can be non-linear.

Heating comprises passing a portable surface heater or propane heat torch over an upper surface of the patterned sheet section after the patterned sheet section has been inserted onto the paved surface. An additional embodiment includes a method of forming multiple paver or paver-like patterns to complete a final predetermined paver pattern onto or into a pavement surface comprising:

(a) a patterned sheet for creating multiple blocks with portions of paver patterns; (b) adhering the patterned sheet to the pavement surface and securing the sheet to the pavement surface via pressure and heat activated adhesives; (c) leaving the patterned sheet on or in the paved surface; thereby;

(g) creating multiple blocks of the portions of the patterns such that paver patterns form a final paver or paver-like uniplanar patterned preform.

In another alternative embodiment, the single isometric thermoplastic, rotatable,

homogeneous quarter round surface patterned preform is produced as thermoplastic sheeting, as described in commonly owned U.S. Patent No. 7,645,503, composed of two or more independent sections. The first section is a grid, which in one specific case replicates the appearance of mortar joints as they would form a brick wall. An additional or second section could for example, replicate bricks which are contained within the grid section. The first and second sections possess a hot melt adhesive spray that is utilized on the bottom surface of the marking pattern to bridge the intersections between the first and second sections to maintain the integrity of the marking pattern for convenience during handling and application to a substrate and packaged for shipment. Preferably the hot melt spray adhesive has

approximately the same softening point range as the patterned sections, to accommodate heat treatment of the marking pattern during application of the marking pattern to the substrate and eventually to the pavement. In this embodiment, the grid could be replaced by continuous thermoplastic sheets formed in the desired shape and pattern. These

thermoplastic sheets may not be inlaid into the pavement but may nevertheless be gently heated as described above to adhere to the underlying asphalt substrate.

In another embodiment the preform can be used for comparatively large thermoplastic surfaces, such as corporate logos, traffic markings, pedestrian walkways, driveways or the like. BRIEF DESCRIPTION OF THE DRAWINGS: The drawings listed below are precise embodiments of the invention, but should not be construed as restricting the spirit or scope of the invention in any way,

FIG. 1 is a top view of a portion of a groutless, homogeneous running bond preformed thermoplastic traffic pattern. FIG. 2a provides a robust running bond pattern of contiguous thermoplastic sheets, as applied.

FIG. 2b provides a color variant robust running bond pattern of contiguous thermoplastic sheets, as applied.

FIG. 2c provides a further color variant robust pattern of contiguous thermoplastic sheets including a pedestrian crosswalk border feature, as applied.

FIG. 3 is a top view of a portion of a groutless, homogeneous herringbone preformed thermoplastic traffic pattern. FIG. 4a provides a robust herringbone pattern of contiguous thermoplastic sheets, as applied.

FIG. 4b provides a color variant robust herringbone pattern of contiguous thermoplastic sheets, as applied. FIG. 4c provides a further color variant robust herringbone pattern of contiguous thermoplastic sheets including a pedestrian crosswalk border feature, as applied.

DETAILED DESCRIPTION OF THE DRAWINGS; Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense. Figure 1 is a top plan view of an adhesively applied thermoplastic preform (patterned preform) [100] bearing a groutless, homogeneous running bond pattern [110] for a pavement surface (as shown in Figure 2b), wherein at least four independent sections, labeled as 1, 2, 3, 4 [120, 122, 124, 126], provide differences selected from the group consisting of: different shades, different colors, and different textures.

In the present disclosure, no two like independent sections [120, 122, 124, 126] are conjoined and grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126] that combined together comprise the patterned preforms [100]. Any lines of separation [128] existing graphically are only shown to discern the conjoining of the independent sections [120, 122, 124, 126].

Figure 1 provides for a single thermoplastic sheet and can be used in single or in combination with itself to generate a robust pattern.

Figure 2a is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] illustrating a groutless, homogeneous running bond pattern [1 10] as applied to a pavement surface (as shown in Figure 2b). The four independent sections [120, 122, 124, 126] are shown providing differences of colors wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. Figure 2a provides a robust running bond pattern [110] of contiguous thermoplastic sheets.

Figure 2b is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] bearing a groutless, homogeneous running bond pattern [1 10] as applied to a pavement surface [210]. The four independent sections [120, 122, 124, 126] are shown providing differences of colors (in a four shade variation from Figure 2a) wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. Figure 2b provides a color variant robust running bond pattern [1 10] of contiguous thermoplastic sheets.

Figure 2c is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] bearing a groutless, homogeneous running bond pattern [110] as applied to a pavement surface [210]. The four independent sections [120, 122, 124, 126] are shown providing differences of colors (in a four shade variation from Figure 2a and 2b) wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. The inclusion of a pedestrian crosswalk border feature [220] is shown.

Figure 2c provides a further color variant robust running bond pattern [110] of contiguous thermoplastic sheets including a pedestrian crosswalk border feature [220]. Figure 3 is a top plan view of an adhesively applied thermoplastic preform [100] bearing a herringbone pattern [310] for a pavement surface [210], wherein at least four independent sections, labeled as 1, 2, 3, 4 [120, 122, 124, 126], provide differences selected from the group consisting of: different shades, different colors, and different textures. In the present disclosure, no two like independent sections [120, 122, 124, 126] are conjoined and grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126] that combined together comprise the patterned preforms [100]. Any lines of separation [128] existing graphically are only to discern the conjoining of the independent sections [120, 122, 124, 126].

Figure 3 provides for a single thermoplastic sheet and can be used singularly or in combination with itself to generate a robust pattern.

Figure 4a is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] bearing a groutless, homogeneous herringbone pattern [310] as applied to a pavement surface [210]. The four independent sections [120, 122, 124, 126] are shown providing differences of colors wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. Figure 4a provides a robust herringbone pattern [310] of contiguous thermoplastic sheets.

Figure 4b is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] bearing a groutless, homogeneous herringbone pattern [310] as applied to a pavement surface [210]. The four independent sections [120, 122, 124, 126] are shown providing differences of colors (in a four shade variation from Figure 2a) wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. Figure 4b provides a color variant robust herringbone pattern [310] of contiguous thermoplastic sheets.

Figure 4c is a photographic depiction of an adhesively applied thermoplastic preform

(patterned preform) [100] illustrating a groutless, homogeneous herringbone pattern [310] as applied to a pavement surface [210]. The four independent sections [120, 122, 124, 126] are shown providing differences of colors (in a four shade variation from Figure 2a and 2b) wherein no two same independent sections [120, 122, 124, 126] are conjoined and wherein grout lines are non-existent in separating any of the four independent sections [120, 122, 124, 126]. The inclusion of a pedestrian crosswalk border feature [220] is shown. Figure 4c provides a further color variant robust herringbone pattern [310] of contiguous thermoplastic sheets including a pedestrian crosswalk border feature [220].

As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.