U.S. patent application number 10/997135 was filed with the patent office on 2005-05-12 for reversible and flexible liner for imprinting a decorative pattern on a malleable surface and a method of using same.
This patent application is currently assigned to Quick Imprint Systems, Inc.. Invention is credited to Jordan, Bradley.
Application Number | 20050097827 10/997135 |
Document ID | / |
Family ID | 46303381 |
Filed Date | 2005-05-12 |
United States Patent
Application |
20050097827 |
Kind Code |
A1 |
Jordan, Bradley |
May 12, 2005 |
Reversible and flexible liner for imprinting a decorative pattern
on a malleable surface and a method of using same
Abstract
A liner for imprinting a decorative pattern on a malleable
surface, such as concrete, and a method of doing same, wherein the
liner is flexible so as to imprint on curved surfaces and
reversible so as to imprint opposing indentations of the decorative
pattern. The liner comprises bottom and top faces, opposing side
edges, and opposing end edges. Due to the flexibility, the opposing
end edges and opposing side edges may contact each other, which
allows for the liner to be used in any curved mold for imprinting
any curved surface. Due to the reversibility, either protruding or
recessed mortar joints may be imprinted on the surface. The method
provides for removably securing the liner to the mold; pouring a
wetted flowable material into the mold that will harden; and
separating the mold and liner combination from the hardened
surface.
Inventors: |
Jordan, Bradley; (Goodman,
MO) |
Correspondence
Address: |
HOVEY WILLIAMS LLP
2405 GRAND BLVD., SUITE 400
KANSAS CITY
MO
64108
US
|
Assignee: |
Quick Imprint Systems, Inc.
|
Family ID: |
46303381 |
Appl. No.: |
10/997135 |
Filed: |
November 24, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
10997135 |
Nov 24, 2004 |
|
|
|
10423619 |
Apr 24, 2003 |
|
|
|
60375611 |
Apr 24, 2002 |
|
|
|
Current U.S.
Class: |
52/21 |
Current CPC
Class: |
E02D 29/02 20130101 |
Class at
Publication: |
052/021 |
International
Class: |
E02D 029/14 |
Claims
1. A reversible liner for imprinting a malleable surface
comprising: a top face having a decorative pattern thereon; and a
bottom face having a decorative pattern thereon, such that either
the top face or the bottom face may be used to imprint indentations
in the malleable surface.
2. The liner as claimed in claim 1, wherein the liner is formed
from an extruded polyethylene copolymer material.
3. The liner as claimed in claim 1, wherein the liner has a width
of approximately one foot to ten feet and a length of approximately
one foot to sixteen feet.
4. The liner as claimed in claim 1, the liner further including
opposing end edges and opposing side edges.
5. The liner as claimed in claim 4, wherein the liner is flexible,
such that the opposing end edges may contact each other and the
opposing side edges may contact each other without damaging the
liner.
6. The liner as claimed in claim 5, wherein the top face of the
liner provides a protrusion and the bottom face of the liner
provides a recess.
7. The liner as claimed in claim 1, wherein an edge of the liner is
provided with a flange, such that an open side of a second liner
may abut the flange to provide a seamless, contiguous pattern.
8. In a liner for imprinting a malleable surface, the liner
comprising opposing end edges, opposing side edges, and top and
bottom faces and having a decorative pattern formed on at least one
of the faces, the liner having a Young's modulus in the range of
approximately 2.00 (kgf/mm.sup.2)/(mm/mm) to 4.00
(kgf/mm.sup.2)/(mm/mm) at approximately 72.degree. F. when having a
size of approximately 0.5 inch wide, 0.078 inch thick, and 4 inches
long.
9. The liner as claimed in claim 8, wherein the liner can be used
to imprint the malleable surface approximately thirty to fifty
times.
10. The liner as claimed in claim 9, wherein the liner is
reversible, such that a second of the at least one faces has an
opposing decorative pattern formed thereon.
11. The liner as claimed in claim 10, wherein for a liner having a
size of approximately 1 to 10 feet wide, approximately 1 to 16 feet
long, and approximately 0.03 inch to 1 inch thick, the opposing end
edges may contact each other and the opposing side edges may
contact each other.
12. The liner as claimed in claim 11, wherein the liner may imprint
the malleable surface without first being casted onto a board.
13. A liner having a decorative pattern formed thereon and operable
to be bent so as to imprint the decorative pattern on a curved,
malleable surface without use of a support board.
14. The liner as claimed in claim 13, wherein the liner is formed
from an extruded polyethylene copolymer material.
15. The liner as claimed in claim 13, the liner including opposing
end edges and opposing side edges forming closed and open sides,
respectively, wherein the first side edge is provided with a flange
to form the closed side so that an open side of a second liner may
abut the flange to provide a seamless, contiguous pattern
16. The liner as claimed in claim 15, wherein due to the liner's
flexibility, the opposing end edges may contact each other and the
opposing side edges may contact each other.
17. The liner as claimed in claim 16, wherein the decorative
pattern includes a plurality of raised, concave protrusions to
imprint simulated mortar joints on the malleable surface.
18. A flexible liner for imprinting a malleable surface comprising:
a top face provided with a decorative pattern that includes a
plurality of protrusions; a bottom face provided with a reflection
of the decorative pattern that includes a plurality of recesses;
opposing end edges; and first and second opposing side edges
forming closed and open sides, respectively, wherein the first side
edge is provided with a flange to form the closed side so that an
open side of a second liner may abut the flange to provide a
seamless, contiguous pattern, wherein the flexible liner may be
shaped to imprint the decorative pattern on a curved malleable
surface, such that the opposing end edges may contact each other
and the opposing side edges may contact each other.
19. A method of imprinting a decorative pattern on a curved
malleable surface comprising the steps of: removably securing a
liner providing the decorative pattern to a mold, wherein the mold
is operable to receive a wetted flowable material that when
hardened produces the imprinted malleable surface, and wherein the
mold includes at least one generally curved portion; pouring the
wetted flowable material into the mold; allowing the material to
harden into the malleable surface; and separating the mold and
liner removably secured thereto from the surface.
20. The method as claimed in claim 19, wherein the liner includes
bottom and top faces, opposing end edges, and opposing side
edges.
21. The method as claimed in claim 20, wherein the liner is formed
from an extruded polyethylene copolymer material.
22. The method as claimed in claim 20, wherein the liner has a
width of approximately one foot to ten feet and a length of
approximately one foot to sixteen feet.
23. The method as claimed in claim 22, wherein the liner is
flexible, such that the opposing end edges may contact each other
and the opposing side edges may contact each other.
24. The method as claimed in claim 23, wherein the top face of the
liner provides a protrusion and the bottom face of the liner
provides a recess for producing protrusions and recesses on the
surface.
25. The method as claimed in claim 19, wherein an edge of the liner
is provided with a flange, such that an open side of a second liner
may abut the flange to provide a seamless, contiguous pattern.
26. The method as claimed in claim 19, wherein the liner may used
to imprint the malleable surface without first being casted onto a
board.
Description
RELATED APPLICATION
[0001] The present application is a continuation-in-part and claims
priority benefit, with respect to all common subject matter, of
U.S. application Ser. No. 10/423,619, filed Apr. 24, 2003, entitled
"WALL SYSTEM," and herein incorporated by reference. U.S.
application Ser. No. 10/423,619 claims priority benefit of U.S.
Provisional Application No. 60/375,611, filed Apr. 24, 2002, and
entitled "QUICK SET RETAINING WALL," which is also incorporated
into the present application by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to imprinting decorative
patterns on malleable surfaces, such as concrete. More
particularly, the invention relates to a liner having a decorative
pattern formed thereon and for use in lining a form or mold so that
wetted concrete poured within the form or mold and allowed to set
is imprinted with the decorative pattern. The liner may be used to
imprint both vertical and horizontal concrete sections.
[0004] 2. Description of the Prior Art
[0005] Imprinted concrete has become a popular, attractive, and
inexpensive way of simulating laid brick, stone, or rock. Although
many methods and devices are known for imprinting concrete, most
have drawbacks. For example, applicant invented a method and device
for imprinting concrete using a roller, disclosed in U.S. Pat. No.
5,033,906 (the '906 patent), which is herein incorporated by
reference. The roller is primarily designed for imprinting a
pattern on only a top face of poured, semi-hardened concrete that
is relatively flat.
[0006] To imprint both a bottom and a top face of a concrete
section, such as both sides or faces of a concrete wall, prior art
methods use a rigid liner approximately four feet wide,
approximately nine feet long, and approximately one-half to one
inch thick. The liner has a brick, stone, or rock pattern formed
thereon, and the liner is glued or otherwise casted to a thick,
heavy plywood board. The rigid liner is casted to the plywood board
during manufacture, such that end users of the liner cannot remove
the liner from the plywood board without damaging the liner. The
end user lines a frame defining the desired concrete section with
the board and liner combination, with the formed pattern on the
liner facing upwards. Wetted concrete is then poured over the liner
and allowed to set. The top face of the concrete may then be
imprinted or stamped using the above-described roller or other
known imprinting or stamping methods and devices. Once the concrete
is set, the concrete section is lifted, and the board and liner
combination is separated from the section. Without the board, prior
art liners tear very easily and cannot withstand repeated uses.
[0007] The liner is made of a material that is relatively porous
and thus has a plurality of small pock marks and indentations, such
that the wetted concrete fills the pock marks and indentations.
Once the concrete has hardened, the plurality of filled pock marks
and indentations grip or otherwise hold the liner to the concrete
section. Additionally, the liner is compressible, such that the
wetted concrete compresses against the liner. Therefore, after the
concrete has hardened and the board and liner combination must be
removed from the concrete section, a large amount of force, and
sometimes tools, must be used to separate the board and liner
combination from the concrete section. Every time the liner is used
and subsequently removed from a concrete section, the liner is
damaged because the pock marks and indentations tear and are made
larger by the required force to separate the liner from the
concrete section.
[0008] Additionally, the board is commonly three-quarter inch
cabinet grade plywood approximately four feet wide and nine feet
long so as to approximate the dimensions of the liner. As can be
appreciated, the board is very heavy, and at least two persons are
required to lift the board. Thus, because the hardened concrete set
into the plurality of pock marks and indentations grips the liner
and because the board and liner combination is very heavy, the
board and liner combination is not easily removed from the concrete
section.
[0009] Importantly, the concrete section must be relatively flat so
as to receive the imprinting from the rigid liner. Because the
liner is rigid, it cannot be curved so as to follow the form of a
curved concrete section. Therefore, known prior art liners allow
for only imprinting flat sections of concrete, which significantly
limits the types or shapes of concrete sections that may be
imprinted.
[0010] Even if the liner was removed from the plywood board, it is
still rigid enough that it could only be curved a very slight
degree. For example, the flexibility of prior art liners can be
compared to cardboard. If the cardboard was folded in half, such
that opposing halves of an inner face of the cardboard touched each
other, then the cardboard would have a permanent crease along the
fold line that could not be removed. Similarly, the prior art rigid
liner does not offer enough flexibility to fold the liner in half,
either along the length of the liner or the width of the liner,
without permanently damaging the liner. Although it is rare that
the liner would need to be folded in such a manner to imprint the
concrete section, such lack of flexibility does severely impede the
concrete sections that may be imprinted. For example, if the
concrete section is curved to a degree to which the prior art liner
cannot be curved, then the curved concrete section cannot be
imprinted with the rigid liner, notwithstanding the fact that the
rigid liner is permanently casted to a rigid plywood board.
[0011] Another disadvantage of prior art rigid liners is that a
pattern is formed on only one face of the liner. The pattern may
comprise recessed joints or protruded joints, but not both. For
example, if the liner is imprinted with a pattern such that the
joints are protruded or bubbled, then when concrete is poured over
the liner and set, the concrete section will have recessed joints.
Conversely, if the liner is imprinted with a pattern having
recessed joints, then when concrete is poured over the liner and
set, the concrete section will have protruded or bubbled joints.
Because the rigid liners are glued or otherwise substantially
permanently mounted to the plywood board, only one face of the
liner can be imprinted with a pattern.
[0012] An even further disadvantage of prior art liners is the type
of board used on which to mount the liner. As noted above, the
three-quarter inch plywood boards are heavy (approximately 240
lbs.), expensive, and inherently cumbersome to use. However, such
large, thick boards are necessary to provide the needed support for
the rigid liner. The boards have a limited use life due to water
from the poured concrete contacting the boards and rotting or
otherwise destroying them, requiring disposal of both the boards
and liners. Even if the boards were capable of more uses, the liner
itself is usually limited to less than twenty uses.
[0013] Accordingly, there is a need for an improved liner and
method of using same for imprinting concrete that overcomes the
limitations of the prior art. More particularly, there is a need
for a liner that allows for imprinting curved sections of concrete.
Additionally, there is a need for a reversible liner imprinted on
both faces of the liner so that either recessed or protruding
joints may be imprinted. Further, there is a need for board
material that is lighter, easier to use, less expensive, and less
consuming of natural resources. Finally, there is a need for a
longer-wearing liner that can withstand numerous uses.
SUMMARY OF THE INVENTION
[0014] The present invention solves the above-described problems
and provides a distinct advance in the art of imprinting malleable
surfaces, such as concrete. More particularly, the present
invention provides a reversible, flexible liner that may be used
for imprinting both flat and curved malleable surfaces with a
decorative pattern.
[0015] The liner of a first preferred embodiment of the present
invention broadly comprises a top and a bottom face; opposing end
edges; and opposing side edges. The liner is generally rectangular
in shape and is extruded to provide a decorative pattern on both
the top and bottom faces. The top face of the liner includes
protrusions for imprinting recessed joints, and similarly, the
bottom face of the liner includes recesses for imprinting
protruding joints.
[0016] The liner is flexible enough that it may fit within any
curved mold for forming a curved concrete section. Additionally,
because the liner is extruded to provide the pattern on both the
top and bottom faces, the liner is reversible to provide imprinting
of both protruding and recessed joints. The liner preferably weighs
approximately six pounds and may be used approximately thirty to
fifty times.
[0017] To form a flat concrete section, the liner is removably
secured to a light, fibrous board, and the board and liner
combination is positioned within a frame sized to form a concrete
section. Wetted, flowable material, such as concrete, is poured on
top of the liner and allowed to harden. Once hardened, the concrete
section is lifted up, and the board and liner combination is easily
removed from the concrete section.
[0018] A liner of a second preferred embodiment is substantially
similar to the liner of the first preferred embodiment, except that
the liner is used to imprint a curved concrete section. For this
embodiment, the liner is preferably secured directly to a mold for
the concrete section, such as a SONOTUBE. The mold may be any
shape, such as circular, rectangular, etc, so as to form a column
or other preferred shape. A location of where end edges of the
liner meet is marked. Wetted concrete is poured into the mold and
allowed to set. Once hardened, the mold is cut along the marked
location so as not to cut the liner. The mold and liner combination
easily removes from the concrete section, and the liner is removed
from the mold so as to create the column or other shape.
[0019] By constructing a liner as described herein, numerous
advantages are realized. For example, the liner of the present
invention is flexible enough to imprint curved concrete sections.
Additionally, because both faces of the liner are provided with the
decorative pattern, the liner may imprint both protruding and
recessed joints as dictated by the aesthetic desires of the user.
Further, the board and liner combination is light and easily
removed from the concrete section. Further yet, the liner of the
present invention is approximately ten times less than prior art
lines. Prior art liners with the plywood board cost approximately
$1200, whereas the liner and board combination of the present
invention costs approximately $120.
[0020] These and other important aspects of the present invention
are described more fully in the detailed description below.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0021] A preferred embodiment of the present invention is described
in detail below with reference to the attached drawing figures,
wherein:
[0022] FIG. 1 is a perspective view of a first preferred embodiment
of a liner for imprinting a decorative pattern on a malleable
surface;
[0023] FIG. 2 is a perspective view of a plurality of concrete
sections, including flat and curved concrete sections, imprinted
using the liner of the first preferred embodiment;
[0024] FIG. 3 is a plan view of the liner of the first preferred
embodiment;
[0025] FIG. 4 is a fragmentary cross-sectional view of the liner
taken through line 4-4 of FIG. 3;
[0026] FIG. 5 is a fragmentary perspective view of the liner
abutting and interconnecting with a second liner;
[0027] FIG. 6 is an exploded fragmentary perspective view of a
frame for forming a concrete section within which is positioned a
board and the liner; and
[0028] FIG. 7 is a perspective view of a liner of a second
preferred embodiment mounted within a curved mold for forming a
curved concrete section.
[0029] The drawing figures do not limit the present invention to
the specific embodiments disclosed and described herein. The
drawings are not necessarily to scale, emphasis instead being
placed upon clearly illustrating the principles of the
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring to FIGS. 1 through 7, a liner 10 for forming
decorative patterns on a malleable surface, such as concrete, and a
method of doing same is constructed in accordance with a first
preferred embodiment of the present invention. Although the liner
10 may be used to imprint any malleable surface, the liner 10 is
ideally configured for imprinting concrete surfaces, and therefore,
imprinting of only concrete surfaces will hereinafter be discussed.
It is understood, however, that the liner 10 and method of using
same of the present invention may be used on all malleable
surfaces.
[0031] Use of the liner 10 in conjunction with the hardening of a
wetted, flowable material, such as concrete, produces a stone,
brick, rock, or marble-like appearance on the face of the concrete.
The liner 10 may be used to imprint decorative patterns on both
generally flat and generally curved surfaces, as illustrated in
FIG. 2 and as illustrated in FIG. 1 of U.S. application Ser. No.
10/423,619, having the same applicant as the present invention and
herein incorporated by reference. Additionally, because the liner
10 is reversible, a single liner 10 may be used to imprint both
recessed and protruded mortar joints, as discussed in more detail
below.
[0032] As illustrated in FIGS. 1 and 3, the liner 10 of the first
preferred embodiment comprises a top face 12 and a bottom face 14,
opposing end edges 16, and opposing side edges 18. The liner 10 is
generally rectangularly-shaped, although it may be any other
polygonal shape or may be curvilinear, and is approximately 3 feet
wide, 6 feet long, and 0.078 inch thick, although the width may
range between 1 and 10 feet, the length may range between 1 and 16
feet, and the thickness may range between 0.03 inch and 5
inches.
[0033] The liner 10 is preferably reversible and extruded to have
the decorative pattern formed thereon. It can be said that the
liner 10 comprises a substrate 11 having the decorative pattern
formed thereon, such that top and bottom faces 12,14 of the liner
10 present opposing sides of the pattern that may then imprint
opposing indentations on the concrete section, as illustrated in
FIG. 1. In particular, if the pattern on the top face 12 has
protruded or bubbled mortar joints 20, then the pattern on the
bottom face 14 has recessed mortar joints 22, as best illustrated
in FIGS. 1 and 4. Thus, the pattern formed during the extrusion
process of manufacturing the liner 10 includes raised, concave
protrusions 20 on the top face 12 and generally bowl-shaped
recesses 22 on the bottom face 14 for producing simulated recessed
or protruding mortar joints 20, respectively. If it is desired that
the imprinted pattern on the concrete section have protruded joints
20, then the bottom face 14 of the liner 10 having recessed joints
22 should be adjacent the poured concrete, as further discussed
below. Conversely, if it is desired that the imprinted pattern on
the concrete section have recessed joints 22, then the top face 12
of the liner 10 having protruded joints 20 should be adjacent the
poured concrete. It can also be said that the patterns on the top
and bottom faces 12,14 are reflections of each other, such that the
pattern on the bottom face 14 provides a reflection of the pattern
on the top face 12.
[0034] The liner 10 is preferably flexible and may be rolled or
bent, such that for a liner 10 having the preferred size discussed
above (approximately three feet wide, six feet long, and 0.078 inch
thick), the opposing end edges 16 of the liner 10 can contact each
other and the opposing side edges 18 can contact each other without
damaging the liner 10, as partially illustrated in FIG. 1. The
liner 10 is preferably made of a synthetic resin, such as a
polyethylene copolymer material, which may be extruded to form a
plurality of patterns. Due to the lightweight material of the liner
10, the liner 10 weighs only approximately 6 pounds. Further due to
the material of the liner 10 and to the below-described method of
using the liner 10, the liner 10 may be used for approximately
thirty to fifty uses.
[0035] One of the opposing side edges 18 of the liner 10 includes a
flange 24 to provide a closed side 26 for the liner 10, as best
illustrated in FIG. 4. The other opposing edge 16 does not have a
flange so as to provide an open side 28 for the liner 10, as also
illustrated in FIG. 1. Immediately adjacent the flange 24 is a mold
for a joint 30, similar to the extruded joints 20,22 otherwise
forming the decorative pattern. Two or more liners 10 having closed
and open sides 26,28 may be interconnected by abutting the flange
24 on the closed side 26 of the liner 10 against an open side 28'
of a second liner 10', as illustrated in a slightly offset
configuration in FIG. 5. Because the pattern formed on each liner
10,10' is substantially exactly the same, aligning the open side
28' with the closed side 26 provides for a seamless, contiguous
pattern. Additionally, both end edges 16 of the liner 10 are open
ends, similar to the open side, so that two or more liners 10,10'
may abut end-to-end (not shown) without interfering or otherwise
destroying the seamlessness of the pattern. Therefore, the
imprinted concrete surface will show no seam where two liners meet,
so as to provide the contiguous pattern.
[0036] As noted above, the liner 10 is flexible and is operable to
imprint curved surfaces. To determine the flexibility of the liner
10, a tear test complying with the test method found in ASTM D
624-00, entitled "Tear Strength of Conventional Vulcanized Rubber
and Thermoplastic Elastomers," was performed on the liner 10 by
Midwest Research Institute of Kansas City, Mo.
[0037] The results of the tear test are provided in Tables 1-3
below. Samples of the liner material were subjected to a tear force
at three temperatures: cold--32.degree. F. (0.degree. C.);
ambient--72.degree. F. (23.degree. C.); and hot--131.degree. F.
(55.degree. C.). The liner 10 was cut into Type-C test specimens as
described in the referenced ASTM test method. The size of each
liner specimen before testing was approximately 0.5 inch (12.7 mm)
wide; approximately 0.078 inch (1.98 mm) thick; and approximately 4
inches (101.6 mm) long. An Instron machine, Model 4505, was used to
conduct the test. The Instron machine was positioned in an
environmental chamber for testing at the three, above-referenced
temperatures. Prior to testing, the Instron machine was calibrated
against known weights. An extensometer to measure the displacement
by the Instron machine was selected, and the accuracy of the
extensometer was verified against dial calipers. A digital
thermocouple was used to measure the temperature within the
environmental chamber during the tests.
[0038] The ASTM test method D 624-00 measures the tear strength of
a material. "Tear strength" is hereinafter defined as the amount of
force required to tear a known thickness of a material. The tear
strength is a good indicator of the durability of a material when
subjected to shear type tearing forces. The ASTM test performed
also determined the Young's modulus, which is also referred to as
the "elastic modulus" and is defined in the CRC Handbook of
Chemistry and Physics, 80th ed., as the ratio of stress to
corresponding strain in the tension or compression of a body below
its elastic limit.
[0039] The Instron machine gripped each liner specimen with a grip
distance of approximately 3 inches (76.2 mm). The Instron machine
then pulled the liner specimen with a known, measured force. The
results of the tests are as follows:
1TABLE 1 Testing at 32.degree. F. Load/Width Max Tear Stress at
Strain at Load/Width Young's at Max Load Resistance Max Load Max
Load at Yield Modulus (kgf/mm) (kgf/mm) (kgf/mm.sup.2) (mm/mm)
(kgf/mm) (kgf/mm) Sample 1 1.73 11.07 0.87 0.20 1.73 5.11 Sample 2
1.71 10.94 0.86 0.23 1.71 4.59 Sample 3 1.87 11.96 0.94 0.23 1.87
5.59 Sample 4 1.65 11.87 0.94 0.23 1.85 6.03 Sample 5 1.70 10.91
0.86 0.21 1.70 5.20 Sample 6 1.88 12.03 0.95 0.24 1.88 5.98 Sample
7 1.72 11.01 0.87 0.23 1.72 5.10 Sample 8 1.75 11.20 0.88 0.23 1.75
4.87 Sample 9 1.67 10.69 0.84 0.23 1.67 4.11 Sample 10 1.82 11.69
0.92 0.23 1.82 5.71 Sample 11 1.68 10.77 0.85 0.25 1.68 4.36
Average 1.76 11.29 0.89 0.23 1.76 5.15 Standard 0.08 0.50 0.04 0.01
0.08 0.64 Deviation Variance 0.01 0.25 0.00 0.00 0.01 0.40
[0040]
2TABLE 2 Testing at 72.degree. F. Load/Width Max Tear Stress at
Strain at Load/Width Young's at Max Load Resistance Max Load Max
Load at Yield Modulus (kgf/mm) (kgf/mm) (kgf/mm.sup.2) (mm/mm)
(kgf/mm) (kgf/mm) Sample 1 1.39 8.89 0.70 0.27 1.39 2.93 Sample 2
1.48 9.49 0.75 0.26 1.48 3.10 Sample 3 1.53 9.81 0.77 0.26 1.53
3.30 Sample 4 1.66 9.95 0.78 0.27 1.55 3.26 Sample 5 1.39 8.93 0.70
0.26 1.39 3.14 Sample 6 1.39 8.90 0.70 0.25 1.39 3.36 Sample 7 1.22
7.83 0.62 0.25 1.21 2.83 Sample 8 1.23 7.90 0.62 0.25 1.23 2.52
Sample 9 1.37 8.79 0.69 0.26 1.37 3.33 Sample 10 1.41 9.03 0.71
0.27 1.41 2.95 Sample 11 1.35 8.66 0.68 0.26 1.35 2.83 Sample 12
1.21 7.75 0.61 0.26 1.21 2.57 Average 1.38 8.83 0.70 0.26 1.38 3.02
Standard 0.11 0.73 0.06 0.01 0.11 0.30 Deviation Variance 0.01 0.53
0.00 0.00 0.01 0.09
[0041]
3TABLE 3 Testing at 131.degree. F. Load/Width Max Tear Stress at
Strain at Load/Width Young's at Max Load Resistance Max Load Max
Load at Yield Modulus (kgf/mm) (kgf/mm) (kgf/mm.sup.2) (mm/mm)
(kgf/mm) (kgf/mm) Sample 1 0.86 5.52 0.44 0.31 0.86 1.12 Sample 2
0.77 4.91 0.39 0.32 0.77 1.08 Sample 3 0.82 5.23 0.41 0.31 0.82
0.98 Sample 4 0.75 4.81 0.38 0.30 0.75 0.92 Sample 5 0.84 5.36 0.42
0.32 0.84 1.11 Sample 6 0.80 5.10 0.40 0.30 0.80 1.12 Sample 7 0.84
5.37 0.42 0.31 0.84 1.02 Sample 8 0.90 5.74 0.45 0.32 0.90 1.15
Sample 9 0.87 5.58 0.44 0.31 0.87 1.07 Sample 10 0.90 5.80 0.46
0.30 0.90 1.13 Average 0.83 5.34 0.42 0.31 0.83 1.07 Standard 0.05
0.33 0.03 0.01 0.05 0.07 Deviation Variance 0.00 0.11 0.00 0.00
0.00 0.01
[0042] A non-ASTM flex test was also performed by Midwest Research
Institute on a sample of the liner 10. The sample size was
approximately 0.5 inch (12.7 mm) wide; approximately 0.078 inch
(1.98 mm) thick; and approximately 4 inches (101.6 mm) long. This
test comprised firmly holding the sample of the liner 10 between a
tester's thumb and index finger using both hands to form a small
flex radius of approximately one-half inch. The sample was then
flexed .+-.90.degree. from a generally flat state when positioned
between the thumb and index finger. The sample was flexed rapidly
more than fifty times. This test was done at room temperature on
several samples, and each of the samples showed no cracks, breaks,
or other changes in the surface of the material. The test was
repeated at 32.degree. F. with the same results. The results of
this test demonstrate a high degree of flexibility and durability
when compared to most other materials.
[0043] A second, non-ASTM test performed by Midwest Research
Institute was a ductility test, which assesses the durability of a
material. The ductility test is a 180.degree. double bend test
comprising bending the material back on itself in a tight radius
bend. Like the above-discussed test, a sample of the liner 10 was
used, with the sample size being approximately 0.5 inch (12.7 mm)
wide; approximately 0.078 inch (1.98 mm) thick; and approximately 4
inches (101.6 mm) long. The test comprised bending the sample
180.degree. from a beginning generally flat, at rest position, such
that opposing ends of the same face of the sample touched each
other. The sample was then bent 360.degree., such that opposing
ends of the opposite face touched each other. The sample was bent
in a tight radius bend so as to show a break in the face(s) of the
sample. This test is commonly performed to show breaks in an upper
surface of sheet metal, such as aluminum or steel. The harder the
material, the more quickly cracks begin to show. For ductile
aluminum, breaks will begin to show after one double bend. Hard
aluminum will show serious cracks on the first bend. Hard steel
will break before the first bend is complete. The test on the
sample of the liner 10 was run at 32.degree. F. because cold
testing is most detrimental. The sample of the liner 10 withstood
ten double bends without cracking. In the course of the first two
to three bends, the sample thinned substantially at the bend point
to form a "hinge" line. Thereafter, the hinge line did not appear
visually to change or weaken.
[0044] The liner 10 is also preferably dense so as not be
compressible. The liner 10 thus resists compression by the concrete
while the concrete is hardening or curing. Further, unlike prior
art liners, a board need not be used with the liner 10 to provide
support while the concrete is hardening. The liner 10 can be used
to imprint the concrete surface without a board or any backing,
except for a form or mold, as described below.
[0045] The method of the first preferred embodiment comprises the
steps of preparing a form or mold 32 in the shape of a concrete
section 34 to be formed, wherein the form or mold 32 is generally
flat and horizontal; laying a board 36 for the liner 10 within the
form 32; removably securing the liner 10 to the board 36; if more
than one liner 10 is required for imprinting the concrete section
34, laying a board (not shown) and corresponding liner (not shown)
for the remaining area of the form 32; pouring the concrete into
the form 32; allowing the concrete to set so as to form the
concrete section 34; lifting the concrete section 34 from the form
32; and removing the board 36 and liner 10 from the concrete
section 34.
[0046] The step of preparing the form 32 for the concrete section
34 is well known in the art and generally comprises measuring an
area of the concrete section 34 to be formed and outlining the area
with a support frame 38 strong and stable enough to hold the wetted
concrete in the desired position while it is hardening. Other
methods of preparing the form 32 may be used, as are also well
known in the art.
[0047] Because the liner 10 is to be removably secured to the board
36, and the board 36 is to be positioned within the form 32, the
form 32 must be generally flat. Therefore, a bottom face 40 of the
concrete section 34, i.e., the face that is adjacent the liner 10
removably secured to the board 36, will be generally flat. Thus,
the board 36 described serves to provide a flat surface for the
wetted concrete when forming the concrete section; the board 36 is
not required to support the liner 10. Preferably, the wetted
concrete is poured such that a top face 42 of the concrete section
34 is also generally flat, although such is not required if the top
face 42 is not to be imprinted with the decorative pattern. It is
to be understood that deviations in the geometry of the top face 42
of the concrete section 34 across relatively large surface areas
does not affect the ability to imprint the top face 42 of the
concrete section 34 with the roller disclosed in applicant's '906
patent. However, to use the liner 10 of the present invention to
imprint the bottom face 40 of the concrete section 34, the bottom
face 40 must be generally flat. It can be appreciated that the
larger an area of the liner 10, the less the necessity that the
bottom face 40 be generally flat. A method for imprinting a curved
concrete section is described below in a second preferred
embodiment.
[0048] The board 36 is preferably approximately the width and
length of the liner 10, and the board 36 is approximately two
inches in thickness, although the thickness may range between
one-half inch and ten inches. If necessary, the board 36 may be cut
to fit the form 32 of the concrete section 34. The board 36 is
preferably made of a fibrous, natural material, such as a paper
product, and preferably, the board 36 is made of recycled material,
although any lightweight, sturdy material that may removably
receive the liner 10 may be used. The board 36 may be used
approximately two to four times before it no longer sufficiently
provides a flat surface for the liner 10 and must be discarded.
Even with the above-described dimensions, the board 36 is light
enough that one person can easily lift the board 36. Further,
because the board 36 is preferably made of recycled material, the
board 36 is substantially less expensive than prior art plywood
boards and is a more efficient use of natural resources.
[0049] The liner 10 is preferably secured to the board 36 by
stapling the liner 10 to the board 36, although any method of
removably securing the liner 10 to the board 36 without
substantially damaging the liner 10 may be used. Once the board 36
is positioned within the form 32, the liner 10 is removably secured
to the board 36. Alternatively, the liner 10 may be removably
secured to the board 36 prior to positioning the board 36 within
the form 32. If more than one board 36 and liner 10 combination is
being used to imprint the concrete section 34, then multiple board
36' and liner 10' combinations must be positioned within the form
32, such that the liners 10,10' abut as described above to provide
a seamless, contiguous pattern. Once the board 36,36' and liner
10,10' combinations are positioned within the form 32, the concrete
or other wetted flowable material may be poured over the liners
10,10' and allowed to set. As the concrete sets, the pattern is
imprinted on the bottom face 40 of the concrete section 34. If the
top face 42 of the concrete section 34 is to be imprinted, upon
reaching a predefined hardness, the top face 42 is also imprinted
with the decorative pattern using the roller or other known
imprinting devices and methods.
[0050] At the time of removably securing the liner 10 to the board
36, the user must determine which face 12, 14 of the liner 10
should be facing upwards to be in contact with the poured concrete.
As noted above, the liner 10 of the present invention is reversible
so as to provide opposing indentations in the concrete section 34,
i.e., either recessed joints 22 or protruded joints 20. Depending
on the preferred aesthetic, the reversible liner 10 will provide
different impressions, as described above.
[0051] It is also noted that the liner 10 shape may not be the same
shape as the form 32. As such, the liner 10 may be easily cut to
fit the shape of the form 32. The liner 10 pieces may then be taped
together, such as by using duct tape, to the liner's original
shape.
[0052] After the concrete has hardened to the desired level, the
concrete section 34 is lifted from the form 32. Preferably, the
liner 10 is coated with a release agent prior to the concrete being
poured, such that the board 36 and liner 10 combination is easily
removed from the concrete section 34. The release agent is
preferably concrete form release oil, but any suitable release
agent may be used, such as diesel oil, a bio-degradable based food
or animal oil, or a liquid release for rubber stamps. Use of the
release agent protects the liner 10 and extends the use life of the
liner 10. Use of the release agent is not required, however, and
the board 36 and liner 10 combination may still be removed from the
concrete section 34 without use of the release agent.
[0053] Applicant has found that in most instances, the board 36 and
liner 10 combination falls away from the concrete section 34
without any or very little interaction by the user of the present
invention. The maximum amount of work required by the user to
separate the board 36 and liner 10 from the concrete section 34 is
gently pulling on the board 36 by only one user with the user's
hand. Therefore, neither tools nor multiple users are required to
separate the board 36 and liner 10 from the concrete section 34,
and separation can be accomplished in less than ten seconds. The
ease of use of the present invention thus provides a significant
improvement over prior art boards and liners that require more work
and time to separate the board and liner from the concrete
section.
[0054] As illustrated in FIG. 7, to imprint the decorative pattern
on a vertical concrete section 134 or a curved concrete section
134, the second preferred embodiment of the present invention
provides for removably securing a liner 110, substantially similar
to the liner 10 of the first preferred embodiment, to a mold 132,
wherein the mold 132 is in the shape of the desired concrete
section 134; positioning the mold 132 in a desired location for the
concrete section 134; if applicable, marking a location in the mold
132, indicated at letter A in FIG. 7, of where end edges 116 of the
liner 110 abut within the mold 132; if required, positioning
reinforcing material 144 in the mold 132, such as rebar; pouring
wetted concrete or other wetted, flowable material into the mold
132 and allowing it to set; if applicable, once the concrete has
set, cutting the mold 132 along the marked location A; and
separating the mold 132 and liner 110 combination from the concrete
section 134. Unlike the first preferred embodiment, the mold 132
need not be generally flat and horizontal; instead, the mold 132
may be a generally rectangularly-shaped, upstanding tube; a
cylindrical tube; a long, thin rectangular shape, such as for a
wall; or any other desired shape or form. Additionally, the entire
mold 132 need not necessarily be curved; instead, only a portion of
the mold 132 may be curved. The liner 110 is removably secured
directly to the mold 132, without use of the board 36 of the first
preferred embodiment. As illustrated in FIG. 7, the liner 110 is
removably secured to the cylindrical tube 132, commonly referred to
in the art as a SONOTUBE and available from Sonoco of Hartsville,
S.C. SONOTUBEs are often used to form cylindrical concrete pillars.
The illustration of the cylindrical tube in FIG. 7 is for
illustrative purposes only, and as noted above, any mold 132 of any
shape or form may be used.
[0055] As is well known in the art, to form the concrete pillar or
section 134, the SONOTUBE or other mold 132 is positioned where the
concrete section 134 is to be positioned. Alternatively, after the
concrete section 134 has been formed, a crane or other similar
mechanism may be used to position the concrete section 134. The
mold 132 is then supported by wood beams 146 or other suitable
mechanism so that it will not move while the wetted concrete is
being poured and is setting. Rebar 144 is positioned within the
mold 132 to reinforce and support the concrete section 134. As
noted above, before positioning the mold 132 in the desired
location, the flexible liner 110 is removably secured to the inside
of the mold 132, such that the desired decorative pattern is facing
inwards away from the mold 132. Additionally, the release agent is
preferably applied to the liner 110. The liner 110 may be removably
secured to the mold 132 using screws, staples, or other suitable
securing mechanism that allows for removal of the liner 110 without
causing damage to the liner 110.
[0056] If the liner 110 is curved within the mold 132, then
preferably, the location A where the opposing end edges 116 of the
liner 110 meet is marked on the mold 132, such that after the
concrete has set, the mold 132 may be cut along the marked location
A so as to not cut the liner 110. Once the concrete is set and the
mold 132 is cut, the mold 132 and liner 110 combination is
separated from the concrete section 134. It can be appreciated that
the more curved the mold 132 is, the more desirable it is that the
mold 132 and liner 110 combination separates easily from the
concrete section 134. Due to the material of the liner 110 and the
applied release agent, the mold 132 and liner 110 combination
separates easily from the concrete section 134. Applicant has found
that even without use of the release agent, the mold 132 and liner
110 combination separates easily from the concrete section 134.
However, as noted in the first preferred embodiment, application of
the release agent extends the use life of the liner 110.
[0057] As noted above, the flexible liner 110 may be removably
secured within any shape mold 132. This advantageously allows for
imprinting any shape concrete section 134, whether it be a vertical
concrete section 134 and/or a curved concrete section 134. For
example, if the mold 132 is a rectangular-shaped mold, the liner 10
can be folded in the 90.degree. corners of the mold 132 without
damaging the liner 10 and still providing a seamless, contiguous
pattern. It is also noted that liners 110 having different
decorative patterns may be used on the concrete section 134
depending on the desired aesthetic. For example, it may be desired
that a front half of a cylindrical concrete section 134 be
imprinted with a first type of decorative pattern, and a rear half
of the concrete section 134 be imprinted with a second type of
decorative pattern. Further, because the liner 110 is reversible,
joints 120, 122 imprinted on the concrete section 134 may be either
recessed or protruded, as discussed above in the first preferred
embodiment. For example, in FIG. 7, protruded joints 120 are facing
outwards towards the mold. Therefore, when the mold 132 and liner
110 are removed from the concrete section 134, the decorative
pattern on the concrete section 134 will have protruded joints
120.
[0058] Although the invention has been described with reference to
the preferred embodiment illustrated in the attached drawing
figures, it is noted that equivalents may be employed and
substitutions made herein without departing from the scope of the
invention as recited in the claims. For example, the liner 10 may
be made of a material that is not as durable as the material
described for the present invention. Such may be desired if the
liner 10 is to be used for a single application. For example, if a
majority of the form or mold 32 is lined with the liner 10, but a
small section of the form or mold 32 is not lined, it may not be
possible to line the small section with the full liner 10 that is
reusable. Therefore, it may be desired to cut a small portion of
the single-use liner 10 to fit the pattern within the form or mold
32.
[0059] The liner 10 may also be provided with different decorative
patterns on each face 12,14 of the liner 10. For example, if the
liner 10 was made slightly thicker, a first pattern may be provided
on the top face 12, and a second pattern may be provided on the
bottom face 14, thus allowing multiple patterns to be imprinted
using the same liner 10. This would be cost-effective for a user
who would not have to purchase two liners to imprint the separate
patterns.
[0060] Having thus described the preferred embodiment of the
invention, what is claimed as new and desired to be protected by
Letters Patent includes the following:
* * * * *