Formliner and method of use
AssigneePrime Forming & Construction Supplies, Inc., dba Fitzgerald Formliners
InventorsEdward Daniel Fitzgerald, Brian Eugene Sheehan
Life of this patent
Estimating the term…
Abstract
A formliner and method of use are provided in order to minimize and/or eliminate visible seaming between interconnected formliners. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. In this manner, a given portion of a first formliner can mate with another given portion of a second formliner in a nested manner. As such, edges of the interconnected formliners can be discreetly hidden along features of the formliner pattern to reduce and/or eliminate visible seaming between the formliners.
Claims33
A formliner for use in creating a decorative pattern on an exposed face of cementitious material, the formliner comprising:
- a sheet of material;
- at least one cell formed in the sheet of material;
- and
- at least one rib extending along the cell and forming a boundary of the cell, the rib being formed in the sheet of material and defining a raised profile, the rib comprising:
- a first section defining an exterior surface and an interior surface, the exterior surface of the first section of the rib being configured to face outwardly toward the cementitious material and to define a cross-sectional exterior profile, the first section further defining a recess adjacent to the interior surface thereof, the recess defining an cross-sectional interior profile;
- a second section defining an exterior surface that defines a cross-sectional exterior profile, the cross-sectional exterior profile of the second section being less than the cross-sectional interior profile of the first section;
- at least one opening formed in the first section;
- and
- a transition zone formed in the rib between the first section in the second section to interconnect the first section with the second section, the transition zone defining a variable cross-sectional exterior profile increasing from the cross-sectional exterior profile of the second section to the cross-sectional exterior profile of the first section;
- wherein a first formliner can be interconnected with a second formliner by overlaying the first section of the rib of the first formliner onto the second section of the rib of the second formliner such that the second section of the rib of the second formliner is nested within the recess of the first section of the rib of the first formliner, and wherein exterior surfaces of the first sections of the ribs of the first formliner and the second formliner are flush with each other upon nesting of the second section of the second formliner within the first section of the first formliner, and wherein an opening in the first section of the first formliner mates 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.
A panel for forming a repeated pattern on a rigid surface, the panel comprising:
- a plurality of cells for receiving material to be applied to the surface and being arranged in rows with the cells of each row being offset with respect to cells of an adjacent row;
- a panel periphery bounding the plurality of cells by a plurality of sides;
- each cell comprising a recess portion for receiving the material and being shaped to confer a pattern on the material;
- wherein at least one given side of the panel periphery is formed with cells in offset configuration such that the given side has at least one row with a projecting cell bounded in at least one adjacent row with a non-projecting cell.
A sheet for forming a pattern on a surface of a cementitious material, the sheet comprising rows of recesses, each recess being shaped to impart the pattern to the surface of the material, the recesses in a given row being offset with respect to the recesses in an adjacent row, each recess being surrounded with ridges defining the recess, the sheet being combinable with a similar sheet by means of overlapping at least some of the ridges, wherein a plurality of sheets can be interconnected at their ends to form a junction along ridges of offset recesses such that the sheets are interconnected without a substantial seam at the junction.
A panel for forming a pattern in a curable material, the panel comprising a series of shaped regions for imparting, when curable material is in the regions, the pattern on a wall or the like, the panel formed with the shaped regions each being bounded by ridges, the ridges of the panel being configured to enable the panel to be engageable with another panel to increase the area of application of the pattern, at least one of the ridges of the panel having an open end to allow the ridges of the panel to overlay at least one of the ridges of the other panel.
A method for transferring a decorative pattern to an exposed surface of a curable material, the method comprising:
- 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;
- 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
- placing the curable material against the first and second formliners to transmit a decorative pattern formed by the shaped regions of the first and second formliners onto the exposed surface of the curable material.
Dependencies are inferred from the claim text.