# US 2019/0168415 A1 · Formliner and method of use > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0168415 A1 - Document ID: US20190168415A1 - Status: Published application - Kind: A1 - Application number: 16/200,180 - Filed: 2018-11-26 - Published: 2019-06-06 - Earliest claimed: 2008-09-25 - Assignees: Prime Forming & Construction Supplies, Inc., dba Fitzgerald Formliners - Applicants: Prime Forming & Construction Supplies, Inc., dba Fitzgerald Formliners - Inventors: Edward Daniel Fitzgerald; Brian Eugene Sheehan - Web page: https://patentgrep.com/patent/US20190168415A1 ## CPC - B28B 7/0073: {with moulding surfaces simulating assembled bricks or blocks with mortar joints (B28B7/007 takes precedence)} - E04F 13/147: {with an outer layer imitating natural stone, brick work or the like} - E04F 15/02194: {Flooring consisting of a number of elements carried by a non-rollable common support plate or grid (E04F15/022 takes precedence)} - E04F 15/041: {with a top layer of wood in combination with a lower layer of other material} - E04F 15/082: {with a top layer of stone or stone-like material, e.g. ceramics, concrete or glass in combination with a lower layer of other material} - E04F 21/04: Patterns or templates; Jointing rulers {(profile trowels E04F21/16)} - E04G 9/10: with additional peculiarities such as surface shaping, insulating or heating, permeability to water or air - B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B) - E04F: FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS (windows, doors E06B) - E04G: SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS ## Abstract A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. Thus, a plurality of formliners can be interconnected by overlaying raised sections thereof. Further, the formliner can comprise one or more detents and one or more protrusions to enable engagement between interconnected formliners without requiring adhesives. In this manner, formliners can be interconnected in a nested manner such that visible seaming between the interconnected formliners is reduced and/or eliminated. ## Claims ### Claim at position 1 1-28. (canceled) ### Claim 29 A formliner configured to form a corner in curable material, the formliner comprising: a cell comprising a recessed side, at least a portion of cell configured to contact the curable material; a flange connected to the recessed side of the cell of the formliner; and a rib extending along at least a part of the cell of the formliner, the rib of the formliner comprising an opening having a cross-sectional profile corresponding to an exterior cross-sectional profile of a rib of an other formliner, and at least a portion of the rib of the formliner configured to contact the curable material, wherein the formliner is configured to be assembled with the other formliner to form the corner in the curable material by overlaying the opening of the formliner onto the rib of the other formliner to minimize visible seams in the curable material at the corner, and wherein the flange is configured to extend along at least a part of a cell of the other formliner to facilitate alignment of the formliner with the other formliner. ### Claim 30 (depends on 29) The formliner of claim 29, wherein at least a portion of the flange is movable relative to the recessed side of the cell of the formliner such that an angle between the flange and the recessed side of the cell of the formliner is adjustable. ### Claim 31 (depends on 29) The formliner of claim 29, wherein the opening comprises a recess formed in the rib of the formliner, the recess comprising an interior surface, wherein the recess is configured to nest within the recess the exterior cross-sectional profile of the other formliner. ### Claim 32 (depends on 29) The formliner of claim 29, wherein the opening of the rib of the formliner comprises an edge extending about the rib of the formliner, the edge extending from the recessed side of the cell of the formliner, the edge defining the cross-sectional profile of the opening of the rib of the formliner. ### Claim 33 (depends on 32) The formliner of claim 32, wherein the edge is adjustable to enlarge the opening of the rib of the formliner. ### Claim 34 (depends on 33) The formliner of claim 33, wherein the edge comprises tear-away portions connected to the rib of the formliner, the tear-away portions configured to be detached from the rib of the formliner to enlarge the opening of the rib of the formliner. ### Claim 35 (depends on 29) The formliner of claim 29, wherein the flange is configured to extend behind a surface of the cell of the other formliner that is configured to contact the curable material. ### Claim 36 (depends on 29) The formliner of claim 29, wherein the flange of the formliner is configured to be connected to the other formliner with an adhesive. ### Claim 37 (depends on 29) The formliner of claim 29, further comprising a protrusion connected to the rib at the opening of the rib of the formliner, the protrusion extending into the opening of the rib of the formliner, and wherein the protrusion of the formliner is configured to engage a detent of the other formliner to securely assemble the formliner with the other formliner. ### Claim 38 A formliner configured to form a corner in curable material, the formliner comprising: a cell comprising a recessed side, at least a portion of cell configured to contact the curable material; and a rib extending along at least a part of the cell of the formliner, the rib of the formliner comprising an opening having a cross-sectional profile corresponding to an exterior cross-sectional profile of a rib of an other formliner at a predetermined angle with the other formliner, the opening of the rib of the formliner comprising an edge extending along the cross-sectional profile of the rib of the formliner, and at least a portion of the rib of the formliner configured to contact the curable material, wherein the formliner is configured to be assembled with the other formliner at the predetermined angle to form the corner in the curable material by overlaying the opening of the formliner onto the rib of the other formliner to minimize visible seams in the curable material at the corner, and wherein the edge is adjustable to enlarge the opening of the rib of the formliner depending on the predetermined angle between the formliner and the other formliner. ### Claim 39 (depends on 38) The formliner of claim 38, wherein the edge comprises tear-away portions connected to the rib of the formliner, the tear-away portions configured to be detached from the rib of the formliner to enlarge the opening of the rib of the formliner. ### Claim 40 (depends on 38) The formliner of claim 38, further comprising a flange connected to the recessed side of the cell of the formliner. ### Claim 41 (depends on 40) The formliner of claim 40, wherein the flange is configured to extend behind a surface of the cell of the other formliner that is configured to contact the curable material. ### Claim 42 (depends on 40) The formliner of claim 40, wherein the flange of the formliner is configured to be connected to the other formliner with an adhesive. ### Claim 43 (depends on 40) The formliner of claim 40, wherein at least a portion of the flange is movable relative to the recessed side of the cell of the formliner such that an angle between the flange and the recessed side of the cell of the formliner is adjustable. ### Claim 44 (depends on 38) The formliner of claim 38, wherein the opening comprises a recess formed in the rib of the formliner, the recess comprising an interior surface, wherein the recess is configured to nest within the recess the exterior cross-sectional profile of the other formliner. ### Claim 45 (depends on 38) The formliner of claim 38, further comprising a protrusion connected to the rib at the opening of the rib of the formliner, the protrusion extending into the opening of the rib of the formliner, and wherein the protrusion of the formliner is configured to engage a detent of the other formliner to securely assemble the formliner with the other formliner. ### Claim 46 A method for assembling a first formliner and a second formliner to use for forming a corner in curable material, the method comprising: interconnecting the first formliner with the second formliner to minimize visible seams in the curable material by overlaying an opening of a rib of the second formliner onto at least a portion of a rib of the first formliner at a predetermined angle corresponding to a desired angle of the corner when forming the corner in the curable material; and extending a flange of the second formliner along at least a part of a cell of the first formliner to facilitate alignment of the second formliner with the first formliner, wherein the rib of the first formliner extends along at least a part of the cell of the first formliner and comprises an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material, and wherein the rib of the second formliner extends along at least a part of a cell of the second formliner, wherein the opening of the rib of the second formliner has a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner with the second formliner positioned at the predetermined angle relative to the first formliner. ### Claim 47 (depends on 46) The method of claim 46, further comprising moving at least a portion of the flange relative to the cell of the second formliner to adjust an angle between the flange and the cell of the second formliner to correspond to the predetermined angle. ### Claim 48 (depends on 46) The method of claim 46, further comprising securing the flange of the second formliner to the first formliner.