Patent Grant
10723040
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are incorporated by reference under 37 CFR 1.57 and made a part of this specification.
The present inventions relate generally to concrete formliners and methods of using the same. More specifically, the present inventions relate to an improved formliner with snap fitting components that eliminates the need for using adhesives for interconnecting a plurality of formliners in a pattern. Further, the formliner is configured to reduce and/or eliminate visible seams in order to create a more natural appearance in a finished product.
Decorative masonry and concrete construction have become increasingly popular in recent years. The façades of homes and other buildings that had previously been constructed in very simple and plain concrete are now being replaced with either decorative stone and brick or decorative concrete construction.
As a result of the increased demand for stone and brick work, various improvements have been made in stone and brick masonry and concrete construction. These improvements have lowered the cost for such construction by decreasing the time or skill requirements previously needed to perform such work.
For example, in stone and brick masonry, facings and floors have traditionally constructed by skilled artisans from individual units. However, recent advances have been made in the masonry art which allow artisans to more quickly and accurately perform stone or brick work. In particular, various panels, forms, and mounting systems have been developed that allow individual units to be placed in precise geometric patterns, thus eliminating much of the painstaking effort usually expended by the artisan. This now allows generally unskilled artisans, such as the do-it-yourselfer, to create a high-quality product.
Perhaps more importantly for projects with a tighter budget, advances in concrete construction now allow artisans to create a faux stone or brick appearance in concrete with a formliner. As a result, one may achieve the appearance of stone or brick without the associated cost.
A concrete formliner generally comprises an interior surface onto which concrete is poured. The interior surface of the formliner typically includes a desired pattern or shape that will be transferred to the concrete to form a cured concrete casting. In many cases, the formliner is lined up with additional formliners to create a pattern over a wide area. The concrete casting can be created in a horizontal (such as for tilt up construction) or vertical casting process, and can be pre-cast, or cast-at-site construction.
After the concrete has cured, the formliners are removed from the exposed surface of the concrete, thus revealing the desired pattern or shape. Such patterns or shapes can include faux stone or brick, wave patterns, emblems, etc.
As noted above, in recent years, significant advances have been made in the art of concrete laying. Various techniques and equipment have been developed that allow for the creation of decorative patterns in the concrete, especially a faux stone or brick appearance. The results of such techniques and equipment provide the appearance of stone or brick without the cost.
However, according to at least one of the embodiments disclosed herein is the realization that in using multiple formliners, seams are created between the formliners where the formliners meet. For example, in order to create a large pattern or casting with prior art formliners, the formliners are merely placed together using butt joints, thus creating significant visible seams between the formliners. As a result, the appearance of the exposed surface of the concrete is compromised. An unsightly seam is very easy to notice and takes a substantial amount of time and effort to remove from cured concrete. Further, in large-scale projects, it is simply too cost prohibitive to re-work the cured concrete in order to remove the seams. As such, the seams are simply left in place resulting in an inferior concrete product.
Thus, the present inventions provide for formliners and methods of use. For example, the formliner can have one or more cells and one or more raised sections or ribs, wherein the formliner is shaped and configured to be interconnected with other such formliners to create a pattern or array of formliners which nest with each other such that an applied material provides a natural appearance and does not show seaming between the formliners that were interconnected to create the pattern. As discussed herein, there are various features that can be incorporated into this broad conception of the formliner in order to provide various combinations and embodiments of the formliner. In the present description, the disclosed features can be optionally incorporated into the above-noted formliner and its method of use in any combination. Additionally, Applicants describe these features and methods in copending patent applications, International Patent Application No. PCT/US2009/058489, filed Sep. 25, 2009, U.S. patent application Ser. No. 12/406,896, filed Mar. 18, 2009, and U.S. patent application Ser. No. 12/238,294, filed Sep. 25, 2008, the entireties of which are incorporated herein by reference.
In accordance with yet another embodiment, a method is provided for transferring a decorative pattern to an exposed surface of a curable material. The method comprise providing a plurality of formliners, each formliner comprising one or more shaped regions being bounded by ridges, each formliner defining overlapped ridges and overlapping ridges. The method can comprise engaging a first formliner with a second formliner by overlaying overlapping ridges of the first formliner onto overlapped ridges of the second formliner. For example, the method can comprise abutting an opening formed in the overlapping ridge of the first formliner with a transition zone formed in the second formliner, the transition zone being formed between the overlapped ridge and a non-overlap ridge of the second formliner. The method can also comprise placing the curable material against the first and second formliners, for example, to transmit a decorative pattern formed by the shaped regions of the first and second formliners to the curable material.
In some embodiments, each formliner can comprise non-overlap ridges and at least one opening formed in the overlapping ridges. Thus, the method can further comprise overlaying the overlapping ridges of the first formliner onto the overlapped ridges of the second formliner with a non-overlap ridge of the second formliner extending from an opening of the overlapping ridges of the first formliner. The non-overlap ridge of the second formliner can be interconnected with and extend from the overlapped ridge of the second formliner.
In some embodiments, the non-overlap ridge of the second formliner can be separated from the overlapped ridge of the second formliner by a transition zone formed in the second formliner, and the method further comprises abutting the opening of the first formliner with the transition zone of the second formliner. In some embodiments, the overlapping ridge and the non-overlap ridge can have generally the same exterior cross-sectional profile. The opening can be formed as an open end of the overlapping ridge of the first formliner.
The overlapping ridges of the first formliner can define an interior cross-sectional profile that is greater than an exterior cross-sectional profile of the overlapped ridges of the second formliner. In such embodiments, the method can comprise engaging a third formliner with the first formliner and the second formliner. The third formliner can comprise overlapping ridges and overlapped ridges. One of the first, second, and third formliners can comprise a sub-overlapped ridge section that defines an exterior cross-sectional profile that is less than an interior cross-sectional profile of the overlapped ridges.
For example, the sub-overlapped ridge section can be formed along a corner of a periphery of the third formliner. The method can comprise overlaying an overlapped ridge onto the sub-overlapped ridge section. Thus, in some embodiments, the third formliner can comprise the sub-overlapped ridge section formed along a corner of a periphery of the third formliner, and the first formliner and the second formliner can overlap the third formliner at the sub-overlapped ridge section of the third formliner.
In some embodiments of the method, the first formliner and the second formliner can each comprise at least one row with a projecting cell bordered in at least one adjacent row with a non-projecting cell, and the method can comprise engaging the first formliner and the second formliner with a projecting cell in a first row of the first formliner being positioned adjacent to a non-projecting cell in a first row of the second formliner and a projecting cell in a second row of the second formliner being positioned adjacent to a non-projecting cell in a second row of the first formliner.
Further, in some embodiments, edges the overlapping ridges of the first formliner can extend downwardly toward a bottom portion of respective shaped regions located adjacent to overlapped ridges of the second formliner. The method can comprise placing the curable material against the overlapping ridges of the first formliner such that the edges of the overlapping ridges of the first formliner are urged adjacent to the bottom portion of respective shaped regions to minimize and/or eliminate a seam formed between the edges and the bottom portion of the respective shaped regions.
The method can also comprise: interconnecting a first formliner with a second formliner by overlaying a first section of a rib of the first formliner onto a second section of a rib of the second formliner such that the second section of the rib of the second formliner is nested within a recess of the first section of the rib of the first formliner; and positioning an exterior surface of the first section of the rib of the first formliner flush with an exterior surface of a first section of the rib of the second formliner upon nesting of the second section of the second formliner within the first section of the first formliner.
In such embodiments, the method can further comprise interconnecting a third formliner with the first and second formliners by overlaying the first section of the rib of the first formliner and the second section of the rib of the second formliner onto a third section of a rib of the third formliner. Further, the method can comprise positioning an exterior surface of a first section of the rib of the third formliner flush with the exterior surface of the first section of the rib of one of the first and second formliners upon nesting of the third section of the rib of the third formliner within the first section of the rib of the first formliner and the second section of the rib of the second formliner.
Additionally, the method can further comprise mating an opening in the first section of the first formliner against a transition zone of the second formliner such that visible seams in the decorative pattern are minimized when the first formliner and the second formliner are interconnected in use. The transition zone can be formed between the first and second sections of the rib of the second formliner. Further, the opening can be formed as an open end of the first section of the first formliner.
In some embodiments, the method can comprise engaging a first formliner with a second formliner by overlaying overlapping ridges of the first formliner on to overlapped ridges of the second formliner and causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges.
One of the unique aspects of such a method is that it can be implemented such that no adhesive is used to engage the first formliner with the second formliner. In some implementations, the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can be completed prior to placing the curable material against the first and second formliners. Further, the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can comprise engaging a pair of protrusions of an overlapping ridge with a pair of detents of the overlapped ridge. In this regard, the pair of protrusions can be disposed on opposing sides of the overlapping ridge and the pair of detents can be disposed on opposing sides of the overlapped ridge.
Moreover, the method can also comprise the step of engaging a third formliner with the first formliner and the second formliner. The third formliner can comprise overlapping ridges and overlapped ridges, and one of the first, second, and third formliner comprising a sub-overlapped ridge section. The sub-overlapped ridge section can define an exterior geometry that can be less than an interior geometry of the overlapped ridges. In this regard, the method can further comprise overlaying an overlapped ridge onto the sub-overlapped ridge section. Additionally, the sub-overlapped ridge section can be formed along a corner of a periphery of the first formliner, and the method can comprise overlaying the second formliner and the third formliner onto the first formliner at the sub-overlapped ridge section of the first formliner.
The abovementioned and other features of the inventions disclosed herein are described below with reference to the drawings of the preferred embodiments. The illustrated embodiments are intended to illustrate, but not to limit the inventions. The drawings contain the following figures:
While the present description sets forth specific details of various embodiments, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting. Furthermore, various applications of such embodiments and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein.
As generally discussed above, embodiments of the present inventions are advantageously configured in order to enhance the aesthetic finish of a concrete structure. In particular, embodiments disclosed herein can be used to create a natural, seamless appearance of brick, stone, and other types of materials in a concrete structure.
In contrast to prior art formliners that produce an inferior quality product, the structures of embodiments of the formliner disclosed herein, which can also be referred to as a panel or sheet, allow the formliner to create decorative patterns that are visually superior to results provided through the prior art. These significant advantages are due at least in part to the nesting arrangement of the variable size channels of embodiments of the formliner disclosed herein. In particular, the formliner can comprise one or more large interconnection sections and one or more small interconnection sections such that a plurality of formliners can be interconnected at their respective large and small interconnection sections. When interconnected, the plurality of formliners can define one or more generally continuous dimensions or shapes of raise portions thereof. For example, the large and small interconnection sections can configured as nesting semi-cylinders that form a rib structure. Additional advantages and features of embodiments of the formliner are discussed further below.
In some embodiments, it is contemplated that the formliner can be attached to another formliner and/or a form work by means of an adhesive. The adhesive can be disposed on a rear surface or back of the formliner and/or onto a front surface of the formliner. For example, the adhesive can be disposed on the front surface along a rib or ridge that will be overlaid by a portion of another formliner.
In some embodiments, the adhesive can be applied to the formliner at the site. For example, the adhesive can be applied or sprayed onto the formliner. However, in other embodiments, the formliner can comprise an adhesive that can be activated or exposed in order to enable adhesive attachment of the formliner to another formliner or to a form work. In such embodiments, the adhesive can be pre-applied to the formliner and can be exposed by removing a cover strip or activated by dampening with a liquid such as water or otherwise. As such, by peeling away a cover strip or by providing moisture to the adhesive, the adhesive can be activated to adhesively attach the formliner to another formliner or to a form work. As noted above in this manner, the formliner can be securely attached another formliner in a pattern and/or to a form work to facilitate handling and placement of the formliner.
Embodiments of the formliner and formliner components disclosed herein can be manufactured using any of a variety of processes. For example, it is contemplated that some embodiments can be formed using a sheet and a vacuum forming operation. Other manufacturing processes such as injection molding, stamping, extrusion, etc. can also be used.
With reference now to the figures,
In some embodiments, the cells 104 can comprise a recessed portion of the formliner 100. The recessed portion of the cell 104 can be configured to receive a curable material to which a pattern of the formliner can be conferred or transferred. The cells 104 can be uniformly sized. For example, the cells 104 can be rectangularly shaped. As discussed below, embodiments of the formliner 100 can implement other shapes, depths, and sizes of the cells 104.
As illustrated in the embodiment of
Additionally, the embodiment illustrated in
The embodiment illustrated in
In many cases, the exposed surface of a given structure, such as a wall, walking area, or the like, consists of a large surface area. In order to cover the entire area, several formliners must be used. As shown in the formliner assembly of
As discussed above,
In accordance with some embodiments, the formliner 100 illustrated in
Moreover, in some embodiments, edges of each of the respective formliners 120, 122, and 124 can lie along a corner or edge feature of the decorative pattern. As such, when a curable material is placed in against the formliners and takes the shape, in this case of a rectangle having right-angle corners, an edge 127 of the formliner 122 forms a portion of the corner of the molded or formed rectangle and becomes nearly imperceptible. Accordingly, the overlapping edges 127 of the formliner 122 create minimal visible seaming, if at all, between the formliners 120 and 122. This principle is illustrated in greater detail in
Additionally, transition zones or joints 128 are formed where upper surfaces of ribs the formliners 120, 122, and 124 meet. In this regard, the transition zones or joints 128 can be toleranced in order to define an extremely narrow gap between interconnected formliners. Thus, any seaming at the transition zones or joints 128 can also be greatly reduced in order to reduce and/or eliminate visible seaming.
In this regard, the formliner 100 can be configured such that the plurality of ribs 102 includes one or more overlapping portions 130 and one or more overlapped portions 132. In some embodiments, the plurality of ribs 102 of the formliner 100 can be configured to comprise one or more non-overlap portions 134. The overlapping portions 130 can be configured to include an internal cavity with an internal geometry that accommodates the external geometry of the overlapped portions 132. Thus, the overlapped portions 132 can be received within the internal cavities of the overlapping portions 130. The non-overlap portions 134 can extend between overlapping portions 130 and overlapped portions 132. However, the non-overlap portions 134 will not overlap or be overlapped by portions of another formliner win a plurality of formliners are interconnected. When a plurality of formliners is interconnected, the external surface of the overlapping portions 130 can be flush with the external surface of the non-overlap portions 134.
An illustration of this principle is shown in
In
In addition, as discussed below with regard to
Referring still to
Furthermore, although the rib structure is illustrated as being formed by semicylindrical or arch shaped channels, the rib structure can be formed by a rectangular cross-section. In this regard, any variety of shapes can be used. For example, while an embodiment of the formliners discussed herein is generally intended to create an appearance of faux brick, other embodiments of the formliners disclosed herein can be designed to create an appearance of faux stone, including any of various commercial stone such as cut stone, castle rock, sand stone, ledgestone, fieldstone, etc., as well as, wood, river rock, slate, or other materials and variations, which is merely an exemplary and non-limiting list of potential appearances and applications. Thus, the rib structure can be varied and diverse. The dimensions of the rib structure can be variable and allow for irregular patterns as may be seen in natural settings of stone, brick, wood, or other materials.
In addition, referring again to
In this regard, as discussed above, the overlapped portions 206 can define an outer dimension 2. The outer dimension 2 can be less than the outer dimension 1. Further, an inner dimension of the overlapping portions 204 can also be greater than the outer dimension 2 of the overlapped portions 206.
Moreover, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 200 can be configured to define a sub-overlapped section 210. As illustrated in the upper and lower right corners of the formliner 200, the sub-overlapped sections 210 can define an outer dimension 3. The outer dimension 3 can be less than the outer dimension 2 and the outer dimension 1. Further, an inner dimension of the overlapped portions 206 can also be greater than the outer dimension 3 of the sub-overlapped portions 210. Additionally, as described above with respect to
In this manner, a single configuration of a formliner can be used to create a continuous decorative pattern that can be used for any size concrete structure. Advantageously, in contrast to prior art formliners, embodiments of the formliners disclosed herein can be interconnected to create a dimensionally continuous, precise assembly of formliners.
Referring now to
One of the unique features of embodiments disclosed herein is the inclusion of rib openings that allow the overlapped portions of the ribs to be nested within overlapping portions of other ribs and to extend through the rib openings. For example, with reference to
With reference to
In addition, as will be appreciated, once the formliners 120, 122, and 124 are assembled, an edge 330 of the overlapping portion 310 of the formliner 124 will be disposed into a corner 332 formed between the overlapped portion 302 and a cell 334 of the formliner 120. As such, any seaming between the overlapping portion 310 of the formliner 124 and the cell 334 of the formliner 120 will be reduced and/or eliminated.
Similarly, an edge 340 of the overlapping portion 320 of the formliner 122 will be disposed into a corner 342 formed by the overlapped portion 302 and the cell 334. Thus, seaming between the formliner 120 and formliner 122 will be greatly reduced and/or eliminated.
Referring now to
Further,
With continued reference to
As noted above, one of the advantages of embodiments disclosed herein is that seams of overlapped portions of adjacent formliners can be minimized and/or eliminated. In this regard, as illustrated in
Furthermore, the tolerances between the overlapping portion 406 and the overlapped portion 408 can also define a seam 442. Specifically, the distance between the edge 432 and the step 430 can define the seam 442. It is contemplated that the overlapping portion 406 can be toleranced with a longitudinal length such that the edge 432 thereof abuts the step 430. It is also contemplated that as with the seam 440, the compressive forces of the material against the first formliner 400 and the second formliner 402 can serve to reduce the size of the seam 442 to thereby create a superior finished product.
Referring now to
For example, referring generally to a side view similar to that of
Further, in some embodiments, overlapping portions of the ribs of the formliner can be configured to define a variable thickness corresponding to the tapering of the overlapped portions onto which the overlapping portions will be overlaid. As such, the cumulative dimension or configuration of nested or overlaid rib portions can be generally constant. However, it is likewise contemplated that the thickness of overlapping or interconnecting formliners can be generally constant along their respective ribs or ridges.
Additionally, in accordance with at least one of the embodiments disclosed herein is the realization that in forming a pattern of interconnected formliners, the edges along the top, bottom, left, and right sides of a pattern or casting can be carefully arranged in order to ensure a natural appearance. Commonly, a plurality of formliners must be used in order to form a pattern or casting larger than a few square feet in size. Typically, in arranging or interconnecting the formliners, an artisan may begin from a top left corner and work down and across toward the bottom right corner. Thus, the left side and the top side of the pattern or casting can generally be comprised of whole or entire formliners that are interconnected vertically and horizontally. Additionally, formliners located in the center portions of the pattern or casting are also whole or entire formliners. However, according to at least one of the embodiments disclosed herein is the realization that formliners located along the bottom and right sides of the pattern or casting may only be partial sheets. In some embodiments, this deficiency can be overcome by providing alternative embodiments of a formliner that enable the artisan to create desirable bottom and right side edges and/or that can be interconnected with other formliners along a partial length thereof in order to form a clean edge, whether it is a straight edge, curved edge, angled edge, or otherwise.
Accordingly, referring to
In some embodiments, the formliner end portion 500 can be configured to mate with another formliner to form a corner of a pattern, casting, or formwork. In such an embodiment, the formliner end portion 500 can also optionally comprise a ledge recess 522, as described below. For example, the ledge recess 522 can be forwarded by a length of the ribs 504 which comprises a reduced geometry or dimension, as shown in dashed lines in
For example, an exemplary mating arrangement of the formliner end portion 500 with a formliner component or portion is illustrated in
In accordance with the embodiments of the formliner end portion 500 and the corresponding formliner end portion 510 illustrated in
Additionally, in the embodiments illustrated in
However, in other embodiments, the mating ledge 520 can be hingedly or moveably attached to the corresponding formliner end portion 510. For example, the mating ledge 520 can be attached to the corresponding formliner end portion 510 along the length of the cells thereof, but not connected to the ribs 514. In other words, the mating ledge 520 can be separated or cut from the ribs 514 by means of a slit 530. Thus, the slit 530 can allow the mating ledge 520 to be generally flexible or movable relative to the corresponding formliner end portion 510. In such embodiments, the mating ledge 520 can be folded under a portion of the formliner end portion 500. Optionally, the side 502 of the formliner end portion 500 can be eliminated in order to allow the mating ledge 520 to extend to underneath the formliner end portion 500.
However, in other embodiments, such as that illustrated in
Referring to
Referring to
Additionally, as illustrated in the embodiment of
It is contemplated that the embodiment of
Further,
In some embodiments, the formliner 700 can comprise one or more third rib portions 706 that can define a third geometry or configuration that corresponds to one of the first and second geometries or configurations. For example, the first rib portion 702, the second rib portion 704, and the third rib portion 706 can allow the formliner 700 to be overlaid with other formliners 700 in a similar manner as to the formliner 100 described above, and as shown in
As mentioned above with respect to the embodiments disclosed in
Moreover, the formliner 700 can also comprise one or more openings 710 in one or more of the first, second, or third rib portions 702, 704, 706 in order to allow nesting and overlaying of the rib portions with each other, as similarly described above with respect to the embodiments shown in
Additionally, in accordance various embodiments, no adhesive is required to interconnect a plurality of the formliners during set up. As noted above, one of the inventive realizations disclosed herein is that the set up and interconnection of formliners can also be expedited by eliminating the need to apply adhesives to the overlapping joints of interconnected formliners. Thus, the assembly time for a setting up a large pattern of interconnected formliners can be substantially reduced, as well as the cost and parts required, by eliminating the need for adhesives.
In order to provide such a superior benefit, embodiments of the formliners disclosed herein can comprise a snap-fit arrangement that allows overlapping formliners to form an interlocking joint. Thus, the formliners can be securely connected without using adhesives. Further, such embodiments also result in reduced seaming between the formliners where the formliners meet. Furthermore, another of the unique advantages of such an interlocking joint is that the joint is further stabilized and strengthened through the application of force to the overlapping formliners, such as the application of a curable material such as concrete. Therefore, such an interlocking joint not only allows for the elimination of adhesives, but also provides several structural benefits that ultimately create an aesthetically superior product.
Another unique benefit of embodiments disclosed herein is that the interlocking joint can be formed by encasing a rib or ridge of an overlapped formliner with a rib or ridge of an overlapping formliner. In other words, the rib of the overlapping formliner can comprise a recess or cavity into which the rib of the overlapped formliner can be received. The cavity can comprise an opening that is less than the cross-sectional size or passing profile of the rib of the overlapped formliner. Thus, the opening of the cavity must be expanded when the rib of the overlapped formliner is inserted therein. Such expansion can occur through deflection or elastic deformation of the opening. The rib of the overlapped formliner can be inserted into the cavity until being fully received therein such that the opening of the cavity returns to its normal size, thus collapsing around a lower portion or base of the rib of the overlapped formliner. In this manner, the rib of the overlapped formliner is encased within the cavity. The term “snap-fit” can refer to the interference fit, deformation, and subsequent collapsing of the opening to its normal size around the base of the rib of the overlapped formliner. Additionally, the encasing of the rib of the overlapped formliner thereby prevents horizontal and vertical relative movement between the overlapped and overlapping formliners.
In this regard, the interlocking joint and encasing disclosed above is distinct from various other prior art systems, such as that disclosed in U.S. Pat. No. 4,858,410, issued to Goldman (hereinafter “Goldman”).
Thus, although the Goldman reference discloses a brickwork form with dimples, the dimples thereof do not comprise any protrusion or detent, for example, to interlock the dimples 806 of the first form 808 with the dimples of the second form 810. The dimples 806 serve only a locating function when positioning the forms to align the ridges of the forms relative to each other. However, the dimples can easily be dislodged or shifted. Further, it is apparent that loading on the edges of the forms can create deformation of the edges. Because the dimples do not serve to restrict separation between the forms in a vertical direction, such loading can cause the forms to be disengaged and become misaligned. The dimples simply do not interlock the forms or provide any meaningful engagement between the forms that can eliminate the need for adhesives. Indeed, adhesives are required in order to properly adjoin the forms disclosed in the Goldman reference.
In contrast, embodiments disclosed herein provide a secure interconnection and engagement between overlapping formliners. For example, as discussed herein, an embodiment of the formliner can comprise a protrusion and a detent such that a plurality of formliners can be interconnected with the protrusions engaging respective detents such that the formliners are not only restrained in a horizontal direction, but also in a vertical direction. As such, these features can effectively eliminate the need for glues and adhesives required by inferior prior art designs. The Goldman reference simply does not disclose such features and provides no teaching or suggestion of such features.
Embodiments of the formliner and formliner components disclosed herein can be manufactured using any of a variety of processes. For example, it is contemplated that some embodiments can be formed using a sheet and a vacuum forming operation. Other manufacturing processes such as injection molding, stamping, extrusion, etc. can also be used.
With reference now to
In some embodiments, the cells 1104 can comprise a recessed portion of the formliner 1100. The recessed portion of the cell 1104 can be configured to receive a curable material to which a pattern of the formliner can be conferred or transferred. The cells 1104 can be uniformly sized. For example, the cells 1104 can be rectangularly shaped. As discussed below, embodiments of the formliner 1100 can implement other shapes, depths, and sizes of the cells 1104.
As illustrated in the embodiment of
Additionally, the embodiment illustrated in
The embodiment illustrated in
In many cases, the exposed surface of a given structure, such as a wall, walking area, or the like, consists of a large surface area. In order to cover the entire area, several formliners must be used. As shown in the formliner assembly of
As discussed above,
In accordance with some embodiments, the formliner 1100 illustrated in
Moreover, in some embodiments, edges of each of the respective formliners 1120, 1122, and 1124 can lie along a corner or edge feature of the decorative pattern. As such, when a curable material is placed in against the formliners and takes the shape, in this case of a rectangle having right-angle corners, an edge 1127 of the formliner 1122 forms a portion of the corner of the molded or formed rectangle and becomes nearly imperceptible. Accordingly, the overlapping edges 1127 of the formliner 1122 create minimal visible seaming, if at all, between the formliners 1120 and 1122. This principle is illustrated in greater detail in
Additionally, transition zones or joints 1128 are formed where upper surfaces of ribs the formliners 1120, 1122, and 1124 meet. In this regard, the transition zones or joints 1128 can be toleranced in order to define an extremely narrow gap between interconnected formliners. Thus, any seaming at the transition zones or joints 1128 can also be greatly reduced in order to reduce and/or eliminate visible seaming.
In this regard, the formliner 1100 can be configured such that the plurality of ribs 1102 includes one or more overlapping portions 1130 and one or more overlapped portions 1132. The overlapping portions 1130 can be configured to include an internal cavity with an internal geometry that accommodates the external geometry of the overlapped portions 1132. Thus, the overlapped portions 1132 can be received within the internal cavities of the overlapping portions 1130.
The formliner 1100 can be configured to comprise a protrusion and a detent in order to facilitate interconnection between a plurality of formliners. For example, the ribs 1102 can be configured to comprise one or more protrusions 1136 and/or detents 1138. In some embodiments, as shown in
For example, the protrusion 1136 can be disposed on overlapping portions 1130 of the rib 1102, and the detent 1138 can be disposed on overlapped portions 1132 of the rib 1102. As such, when the formliner 1100 is interconnected with other formliners, as shown in
In some embodiments, the plurality of ribs 1102 of the formliner 1100 can be configured to comprise one or more non-overlap portions 1134. The non-overlap portions 1134 can extend between overlapping portions 1130 and overlapped portions 1132. However, the non-overlap portions 1134 will not overlap or be overlapped by portions of another formliner win a plurality of formliners are interconnected. When a plurality of formliners is interconnected, the external surface of the overlapping portions 1130 can be flush with the external surface of the non-overlap portions 1134.
An illustration of this principle is shown in
In
In addition, as discussed below with regard to
As illustrated, some embodiments can be configured such that the corner portions of the ribs are formed to include a protrusion or a detent. Similarly, embodiments can be configured such that the free side edges are formed to include a protrusion or a detent. The arrangement of the protrusions and detents along the corner portions or free side edges can be determined based on the pattern, for example. However, as shown in
In this regard, one of the unique features of some embodiments disclosed herein is that an overlapping rib can define a recess or interior cavity whereinto an overlapped rib of an adjacent formliner can be placed. However, in order to insert the overlapped rib into the recess or interior cavity, an opening of the recess can be expanded to receive the overlapped rib. For example,
Further, the formliner 1122 can be fabricated from a resilient material such that after the rib of the formliner 1120 is inserted within the cavity 1180, the opening 1180 elastically returns to its original dimension 1188. In this manner, the opening 1180 closes around a base of the rib of the formliner 1120. In other words, with the rib of the formliner 1120 received within the recess 1180, the width 1188 of the opening 1180 will return to less than the outer diameter, profile, or dimension 1184 of the rib of the formliner 1120, thus encasing the rib within the recess 1180. This is shown in
The protrusions and the detents can be configured to extend inwardly toward an interior of the rib. It is contemplated that in some implementations, the protrusions and detents can be formed into the formliner during the molding process. For example, the formliner can be vacuum formed with such features included therein. However, it is also contemplated that the protrusions and detents can be formed subsequent to the initial forming operations. Further, although the protrusions and detents can be formed integrally with the formliner, such as by forming the formliner and protrusions and detents of a common sheet of material, these features could potentially be added to the formliner in a finishing step.
Referring again to
Furthermore, although the rib structure is illustrated as being formed by semicylindrical or arch shaped channels, the rib structure can be formed by a generally rectangular or polygonal cross-section, to provide the appearance of a “rake joint.” In this regard, any variety of shapes can be used. For example, while an embodiment of the formliners discussed herein is generally intended to create an appearance of faux brick, other embodiments of the formliners disclosed herein can be designed to create an appearance of faux stone, including any of various commercial stone such as cut stone, castle rock, sand stone, ledgestone, fieldstone, etc., as well as, wood, river rock, slate, or other materials and variations, which is merely an exemplary and non-limiting list of potential appearances and applications. Thus, the rib structure can be varied and diverse. The dimensions of the rib structure can be variable and allow for irregular patterns as may be seen in natural settings of stone, brick, wood, or other materials.
For example, referring now to
In addition, referring again to
Various methods are also provided for manufacturing embodiments of the formliners disclosed herein. Generally, many of the embodiments disclosed herein can be manufactured using material to formation processes such as vacuum or thermoforming, injection molding, and other such processes. Thermoforming with the vacuum assist can be used to achieve superior results for thick or thin gauge formliners.
As will be appreciated by one of skill in the art, the thermoforming process begins with a blank that is heated and placed over a mold. Often, a mating mold can be placed over the heated blank to trap the blank between the mold and the mating mold. Vacuum pressure can also be applied to remove any air between the mold and the blank and thereby further draw the blank into the mold.
In accordance with a unique aspect of some of the methods disclosed herein, the formed sheet can be formed to include excess material length. For example, referring to
Once a blank has been formed into a formed sheet using a thermoforming machine, the formed sheet can be further processed using cutting equipment. In some embodiments, the process can employ a laser-cutting device. A laser can provide superior results by exact dimensioning and tolerancing; however, other cutting devices can also be used. The cutting operation or step allows the rib openings discussed above to be formed for those embodiments in which rib openings are used. However, in all embodiments, the cutting operation or step can be used to remove excess material from the edges of the formed sheet in order to produce a prepared formliner. The cutting operation or step can be particularly important in order to ensure that mating edges properly align with corresponding portions of other formliners. Additionally, the cutting operation or step can be particularly important in ensuring that protrusions and recesses of formliners can be properly engaged in assembling a plurality of formliners.
In this regard, as discussed above, the overlapped portions 1206 can define an outer dimension 1002. The outer dimension 1002 can be less than the outer dimension 1001. Further, an inner dimension of the overlapping portions 1204 can also be greater than the outer dimension 1002 of the overlapped portions 1206.
Moreover, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 1200 can be configured to define a sub-overlapped section 1210. As illustrated in the upper and lower right corners of the formliner 1200, the sub-overlapped sections 1210 can define an outer dimension 1003. The outer dimension 1003 can be less than the outer dimension 1002 and the outer dimension 1001. Further, an inner dimension of the overlapped portions 1206 can also be greater than the outer dimension 1003 of the sub-overlapped portions 1210. Additionally, as described above with respect to
As noted above, in some embodiments, the overlapped portions can comprise one or more detents, and the overlapping portions can comprise one or more protrusions. In this regard, it is contemplated the protrusions and detents can extend along any length of a respective rib. For example, the protrusions and detents can extend along less than the entire length of a respective rib such that the protrusion and/or detent is offset from a corner or end of the respective rib. It is also contemplated that the protrusions and detents can extend continuously or discontinuously along the respective rib. Moreover, it is appreciated that the design and interlocking profile of the formliner can dictate the arrangement, length, and pattern of the protrusions and detents.
In this manner, a single formliner can be used to create a continuous decorative pattern that can be used for any size concrete structure. Advantageously, in contrast to prior art formliners, embodiments of the formliners disclosed herein can be interconnected to create a dimensionally continuous, precise assembly of formliners.
Referring now to
One of the unique features of embodiments disclosed herein is the inclusion of rib openings that allow the overlapped portions of the ribs to be nested within overlapping portions of other ribs and to extend through the rib openings. For example, with reference to
With regard to
In addition, as will be appreciated, once the formliners 1120, 1122, and 1124 are assembled, an edge 1330 of the overlapping portion 1310 of the formliner 1124 will be disposed into a corner 1332 formed between the overlapped portion 1302 and a cell 1334 of the formliner 1120. As such, any seaming between the overlapping portion 1310 of the formliner 1124 and the cell 1334 of the formliner 1120 will be reduced and/or eliminated.
Similarly, an edge 1340 of the overlapping portion 1320 of the formliner 1122 will be disposed into a corner 1342 formed by the overlapped portion 1302 and the cell 1334. Thus, seaming between the formliner 1120 and formliner 1122 will be greatly reduced and/or eliminated.
Further, the seaming can further be reduced in some embodiments wherein the formliners 1120, 1122, 1124 comprise detents and protrusions that facilitate engagement between the formliners 1120, 1122, 1124. As illustrated, the formliner 1120 can comprise detents 1350 that can be engaged by protrusions 1352 of the formliner 1124. Further, the formliner 1120 can comprise detents 1354 that can be engaged by protrusions 1356 of the formliner 1122. Finally, the formliner 1124 can comprise detents 1358 that can be engaged by protrusions 1360 of the formliner 1122.
Furthermore, upon application of a curable material to the formliner assembly illustrated in
Referring now to
Further,
With continued reference to
As noted above, one of the advantages of embodiments disclosed herein is that seams of overlapped portions of adjacent formliners can be minimized and/or eliminated. In this regard, as illustrated in
Furthermore, the tolerances between the overlapping portion 1406 and the overlapped portion 1408 can also define a seam 1442. Specifically, the distance between the edge 1432 and the step 1430 can define the seam 1442. It is contemplated that the overlapping portion 1406 can be toleranced with a longitudinal length such that the edge 1432 thereof abuts the step 1430. It is also contemplated that as with the seam 1440, the compressive forces of the material against the first formliner 1400 and the second formliner 1402 can serve to reduce the size of the seam 1442 to thereby create a superior finished product.
Referring now to
For example, referring generally to a side view similar to that of
Further, in some embodiments, overlapping portions of the ribs of the formliner can be configured to define a variable thickness corresponding to the tapering of the overlapped portions onto which the overlapping portions will be overlaid. As such, the cumulative dimension or configuration of nested or overlaid rib portions can be generally constant. However, it is likewise contemplated that the thickness of overlapping or interconnecting formliners can be generally constant along their respective ribs or ridges.
Additionally, in accordance with at least one of the embodiments disclosed herein is the realization that in forming a pattern of interconnected formliners, the edges along the top, bottom, left, and right sides of a pattern or casting can be carefully arranged in order to ensure a natural appearance. Commonly, a plurality of formliners must be used in order to form a pattern or casting larger than a few square feet in size. Typically, in arranging or interconnecting the formliners, an artisan may begin from a top left corner and work down and across toward the bottom right corner. Thus, the left side and the top side of the pattern or casting can generally be comprised of whole or entire formliners that are interconnected vertically and horizontally. Additionally, formliners located in the center portions of the pattern or casting are also whole or entire formliners. However, according to at least one of the embodiments disclosed herein is the realization that formliners located along the bottom and right sides of the pattern or casting may only be partial sheets. In some embodiments, this deficiency can be overcome by providing alternative embodiments of a formliner that enable the artisan to create desirable bottom and right side edges and/or that can be interconnected with other formliners along a partial length thereof in order to form a clean edge, whether it is a straight edge, curved edge, angled edge, or otherwise.
Accordingly, referring to
In some embodiments, the formliner end portion 1500 can be configured to mate with another formliner to form a corner of a pattern, casting, or formwork. In such an embodiment, the formliner end portion 1500 can also optionally comprise a ledge recess 1522, as described below. For example, the ledge recess 1522 can be forwarded by a length of the ribs 1504 which comprises a reduced geometry or dimension, as shown in dashed lines in
For example, an exemplary mating arrangement of the formliner end portion 1500 with a formliner component or portion is illustrated in
In accordance with the embodiments of the formliner end portion 1500 and the corresponding formliner end portion 1510 illustrated in
Additionally, in the embodiments illustrated in
However, in other embodiments, the mating ledge 1520 can be hingedly or moveably attached to the corresponding formliner end portion 1510. For example, the mating ledge 1520 can be attached to the corresponding formliner end portion 1510 along the length of the cells thereof, but not connected to the ribs 1514. In other words, the mating ledge 1520 can be separated or cut from the ribs 1514 by means of a slit 1530. Thus, the slit 1530 can allow the mating ledge 1520 to be generally flexible or movable relative to the corresponding formliner end portion 1510. In such embodiments, the mating ledge 1520 can be folded under a portion of the formliner end portion 1500. Optionally, the side 1502 of the formliner end portion 1500 can be eliminated in order to allow the mating ledge 1520 to extend to underneath the formliner end portion 1500.
Nevertheless, in other embodiments, such as that illustrated in
Further, as shown in
Referring to
Further, as shown in
Another embodiment of a formliner end portion can be provided which comprises one or more ribs. As noted above, the formliner end portion is an embodiment in which no side is used. Similar to the other embodiments disclosed herein, the formliner end portion can be configured to mate with a corresponding formliner end portion. The embodiment of the corresponding formliner end portion does not include the mating ledge of the embodiment discussed in regard to
It is contemplated that the embodiment of
Further,
In some embodiments, the formliner 1700 can comprise one or more third rib portions 1706 that can define a third geometry or configuration that corresponds to one of the first and second geometries or configurations. For example, the first rib portion 1702, the second rib portion 1704, and the third rib portion 1706 can allow the formliner 1700 to be overlaid with other formliners 1700 in a similar manner as to the formliner 1100 described above, and as shown in
As mentioned above with respect to the embodiments disclosed in
Furthermore, the formliner 1700 can comprise one or more detents 1708 and one or more protrusions 1709. As discussed above with respect to the various other embodiments disclosed herein, the protrusions and detents can enhance the interlocking connection between formliners so as to eliminate the need for adhesives.
Finally, the formliner 1700 can also comprise one or more openings 1710 in one or more of the first, second, or third rib portions 1702, 1704, 1706 in order to allow nesting and overlaying of the rib portions with each other, as similarly described above with respect to the embodiments shown in
In accordance with some embodiments, any of the embodiments of the formliner or combinations thereof can be used in a method of creating a decorative pattern in a curable material, such as a casting, whether vertical or horizontal, a wall, etc. The method can comprise assembling a plurality of any of the formliners disclosed herein to form an assembly. Further, a curable material can be positioned against the assembly, such as by pouring. In this manner, the seams between portions of adjacent formliners can be lessened due to the weight of the material. As the material cures, the seams between the adjacent formliners are reduced and/or eliminated compared to the prior art methods and formliners. As such, one may obtain an aesthetically superior product. Further, any of the embodiments herein provides the additional benefit that the artisan need not perform additional finishing steps to eliminate unsightly seams, thus resulting in a tremendous cost and time savings and efficiency.
Additionally, as discussed above, the formliner 1800 is also shown in a nearly finished state. In other words, the formliner 1800 can still be trimmed in order to produce a finished or prepared formliner. In accordance with some embodiments, the formliner 1800 can comprise one or more rib protrusions 1804 that extend from left and/or right sides of the formliner 1800. As discussed above, these rib protrusions 1804 can be removed prior to use in order to form a rib openings, which are discussed above with respect to other embodiments and shown, for example, in at least
Further, as in the other embodiments disclosed herein, the formliner 1800 shown in
In this regard, as discussed above, the overlapped portions 1852 can define an outer dimension 1862. The outer dimension 1862 can be less than the outer dimension 1860. Further, an inner dimension of the overlapping portions 1850 can also be greater than the outer dimension 1862 of the overlapped portions 1852.
Moreover, as discussed above, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 1800 can be configured to define one or more sub-overlapped sections 1870. Similar to the embodiments discussed above, the sub-overlapped sections 1870 can be provided in the upper and lower right corners of the formliner 1800. Further, the sub-overlapped sections 1870 can define an outer dimension 1872. The outer dimension 1872 can be less than the outer dimension 1862 and the outer dimension 1860. Further, an inner dimension of the overlapped portions 1852 can also be greater than the outer dimension 1870 of the sub-overlapped portions 1870. Additionally, as described above, the formliner 1800 can also be configured to include a plurality of rib openings that are formed upon removal of the rib protrusions 1804. As similarly described above, the plurality of rib openings can be located and configured to correspond with corresponding ribs of adjacent interconnected formliners.
In accordance with some embodiments of the formliners disclosed herein, the sub-overlapped section (such as 210, 304, 1210, 1304, and 1870) can also be configured such that a length of the sub-overlapped section, as measured along the longitudinal direction of the rib, varies to provide optimal fit between overlapping formliners. For example, as shown in
Similar to the embodiment of
In accordance with the embodiment illustrated in
One of the unique advantages of the mold corner 1900 is that the mold corner 1900 helps to reduce the number of scenes and components in a system of formliners used to create a final molded product. In this regard, it is contemplated that the mold corner 1900 can be configured to bend along the folding line 1912 to achieve one of a variety of angular orientations between a first portion 1930 and a second portion 1932 of the mold corner 1900. In this regard, the folding line 1912 can be configured as a thinned area of the mold corner 1900. Further, the folding line 1912 can be configured as a perforated area of the mold corner 1900. Furthermore, the folding line 1912 can also be configured as an indented area of the mold corner 1900. Other variations and configurations of the folding line 1912 can be provided in order to facilitate folding of the mold corner 1900 along the folding line 1912.
For example, it is contemplated that the mold corner 1900 can be configured to provide a 90° bend between the first portion 1930 and the second portion 1932.
As illustrated in the embodiment of
In some embodiments, as illustrated in
Referring again to
In this regard, as discussed above, the overlapped portions 1920 can define an outer dimension 1962. The outer dimension 1962 can be less than the outer dimension 1960. Further, an inner dimension of the overlapping portions 1922 can also be greater than the outer dimension 1962 of the overlapped portions 1920.
Moreover, as discussed above, it is contemplated that in interconnecting formliners with the mold corner and/or mold corners with mold corners and formliners, there are certain points where one or more formliner(s) overlap with one or more mold corner(s). Accordingly, in some embodiments, the mold corner 1900 can be configured to define one or more sub-overlapped sections 1970. Similar to the embodiments discussed above, the sub-overlapped sections 1970 can be provided in the upper and lower right corners of the mold corner 1900. Further, the sub-overlapped sections 1970 can define an outer dimension 1972. The outer dimension 1972 can be less than the outer dimension 1962 and the outer dimension 1960. Further, an inner dimension of the overlapped portions 1920 can also be greater than the outer dimension 1970 of the sub-overlapped portions 1970. Additionally, as described above, the mold corner 1900 can also be configured to include a plurality of rib openings that are formed upon removal of the rib protrusions 1904. As similarly described above, the plurality of rib openings can be located and configured to correspond with corresponding ribs of adjacent interconnected formliners.
In accordance with some embodiments of the formliners disclosed herein, the sub-overlapped section (such as 210, 304, 1210, 1304, 1870, 1970) can also be configured such that a length of the sub-overlapped section, as measured along the longitudinal direction of the rib, varies to provide optimal fit between overlapping formliner(s)/mold corner(s). For example, as shown in
Moreover, the formliners, mold corners, and other components can be formed in any variety of shapes and the ribs or ridges formed in the formliners can serve to provide strength against the weight of the curable material positioned thereagainst without requiring that the formliner be exceedingly bulky, thick, or otherwise heavy. In this regard, embodiments of the formliner can advantageously be used, for example, in tilt-up assemblies that require heavy materials such as rebar without contributing significantly, if even much at all, to the overall weight of the assembly. As such, the formliners allow for the use of less rigorous machinery, such as smaller cranes, etc. Accordingly, the light weight of embodiments of the formliner can allow for additional reductions in cost, time, and labor.
As discussed above, embodiments of the formliners disclosed herein allows the artisan to eliminate and/or reduce any visible seaming between interconnected formliners. Some embodiments of the formliners disclosed herein are able to effectively eliminate such seaming by converging formliner edges into corners above an interconnected formliner and using tight tolerances in mating exposed surfaces of the interconnected formliners.
Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combination or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.
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| Number | Date | Country | |
|---|---|---|---|
| 20190168415 A1 | Jun 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14664053 | Mar 2015 | US |
| Child | 16200180 | US | |
| Parent | 14137733 | Dec 2013 | US |
| Child | 14664053 | US | |
| Parent | 12850510 | Aug 2010 | US |
| Child | 14137733 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12406896 | Mar 2009 | US |
| Child | 12850510 | US | |
| Parent | 12238294 | Sep 2008 | US |
| Child | 12406896 | US |
