U.S. patent application number 11/302411 was filed with the patent office on 2006-06-29 for liner system for forming concrete panels.
Invention is credited to William Brent Baker, Daniel M. Balls, David McKay Balls, Mike Sharp.
Application Number | 20060137273 11/302411 |
Document ID | / |
Family ID | 36609763 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060137273 |
Kind Code |
A1 |
Baker; William Brent ; et
al. |
June 29, 2006 |
Liner system for forming concrete panels
Abstract
A form for creating a pattern in uncured concrete during a
casting process includes a support frame and a perforated
reinforcing structure coupled adjacent to at least a portion of the
support frame. The perforated reinforcing structure includes a
plurality of apertures defined therein. A pliable liner is disposed
at least partially within the plurality of apertures and at least
partially about the perforated reinforcing structure adjacent the
support structure. The pliable liner has a patterned surface formed
thereon for creating a corresponding pattern in uncured concrete
poured adjacent the form.
Inventors: |
Baker; William Brent;
(Heber, UT) ; Balls; David McKay; (Oakley, UT)
; Balls; Daniel M.; (Oakley, UT) ; Sharp;
Mike; (Sandy, UT) |
Correspondence
Address: |
THORPE NORTH & WESTERN, LLP.
8180 SOUTH 700 EAST, SUITE 200
SANDY
UT
84070
US
|
Family ID: |
36609763 |
Appl. No.: |
11/302411 |
Filed: |
December 12, 2005 |
Current U.S.
Class: |
52/426 |
Current CPC
Class: |
B28B 7/007 20130101;
E04G 9/10 20130101; B28B 7/0011 20130101; B28B 7/348 20130101; B28B
7/0073 20130101 |
Class at
Publication: |
052/426 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. A form for creating a pattern in uncured concrete during a
casting process, comprising: a support frame; a perforated
reinforcing structure, coupled adjacent to at least a portion of
the support frame and having a plurality of apertures defined
therein; and a pliable liner, disposed at least partially within
the plurality of apertures and at least partially about the
perforated reinforcing structure adjacent the support structure,
the pliable liner having a patterned surface formed thereon for
creating a corresponding pattern in uncured concrete poured
adjacent the form.
2. The form of claim 1, wherein the support frame includes a
plurality of elongate, tubular members.
3. The form of claim 1, wherein the reinforcing structure is formed
of a substantially planar sheet.
4. The form of claim 1, wherein the pliable material further
includes a compliant polymer.
5. The form of claim 1, wherein the pliable material further
includes polyurethane.
6. The form of claim 1, wherein the perforated reinforcing
structure further includes expanded metal.
7. The form of claim 1, wherein the perforated reinforcing
structure further includes a material selected from the group
consisting of: perforated metal, woven wire sheets and welded mesh
sheets.
8. A form system for creating a pattern in uncured concrete during
a concrete casting process, comprising: a base; a pair of opposing
end wall forms, extending upward from the base and defining end
wall surfaces of a vertical mold cavity for uncured concrete; and a
pair of opposing side wall forms, extending upward from the base
and defining side wall surfaces of the vertical mold cavity, the
opposing side wall forms each including at least: a perforated
reinforcing structure having a plurality of apertures defined
therein; and a pliable liner, disposed at least partially within
the plurality of apertures and at least partially about the
perforated reinforcing structure, the pliable liner having a
patterned surface formed thereon for creating a corresponding
pattern in uncured concrete poured adjacent the form.
9. The system of claim 8, further comprising a lower support gasket
disposable over the base to at least partially define a bottom
surface of the vertical mold cavity.
10. The system of claim 8, wherein the end walls each include: a
perforated reinforcing structure having a plurality of apertures
defined therein; and a pliable liner, disposed at least partially
within the plurality of apertures and at least partially about the
perforated reinforcing structure.
11. The system of claim 8, wherein the side walls and end walls are
operably positionable to form a tetragonal mold cavity.
12. The system of claim 8, further comprising securing structure
associated with the end wall forms and the side wall forms, and
being configured to retain the end wall forms and the side wall
forms in a secure configuration to receive concrete in an uncured
state within the mold cavity.
13. The system of claim 12, further comprising a plurality of side
wall forms, end wall forms and lower gaskets disposed within the
securing structure, to define a plurality of vertical mold cavities
to enable simultaneous vertical casting of multiple concrete
panels.
14. The system of claim 8, wherein the perforated reinforcing
structure further includes a material selected from the group
consisting of: expanded metal, perforated metal, woven wire sheets
and welded mesh sheets.
15. A method for making a form for vertically molding concrete,
comprising the step of: a) obtaining a support frame; b) coupling a
perforated reinforcing structure to at least a portion of the
support frame, the reinforcing structure having a plurality of
apertures disposed therein; and c) disposing a pliable liner at
least partially within the plurality of apertures and at least
partially about the perforated reinforcing structure adjacent the
support frame.
16. The method of claim 15, comprising the further step of: curing
the pliable liner to form a mold surface for retaining uncured
concrete.
17. The method of claim 15, wherein the support frame includes a
plurality of elongate, tubular members.
18. The method of claim 15, wherein the step of coupling the
perforated reinforcing structure further comprises coupling a
substantially planar sheet of expanded metal to at least a portion
of the support frame.
19. The method of claim 15, wherein the pliable liner includes a
compliant polymer.
20. The method of claim 15, wherein the perforated reinforcing
structure further includes a material selected from the group
consisting of: perforated metal, woven wire sheets and welded mesh
sheets.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to a liner system
for use in forming concrete panels used in concrete fences, walls
and related structure.
[0003] 2. Related Art
[0004] Vertically oriented concrete panels have been used for a
number of years in applications including concrete fences, sound
walls, partitions, etc. Concrete panels are often poured and cured
in a central manufacturing area and shipped as cured panels to job
sites, where the panels can be assembled into a fence or similar
structure. It is often desirable to apply a textured, decorative
finish to such concrete panels to enhance the appearance of the
panels. Decorative finishes such as pseudo-brick finishes,
pseudo-rock wall finishes, etc., give the concrete panels a more
aesthetically pleasing appearance, and in some cases, such as in
sound wall applications, can increase the effectiveness of the
concrete panels.
[0005] One type of system developed to pour concrete panels
utilizes vertically-oriented molds between which uncured concrete
is poured and allowed to cure. As the concrete panels are formed
and cured in a vertical orientation, this type of system is known
as a vertical pour system. Some such systems, for example the one
described in U.S. Patent Application Publication No. 20050067551,
utilize vertically oriented, patterned molds which are secured
within a support structure and are filled with uncured concrete. As
the uncured (or wet) concrete is poured into the mold, the weight
of the wet concrete ensures that the concrete fills indentations in
the patterned mold to accurately form a pattern in the finished
panel. Such a process produces a decorative pattern on at least one
side of the panel. Such systems have been found advantageous over
horizontal mold systems because fewer voids appear in the final
product, resulting in an aesthetically pleasing product with
superior physical integrity.
[0006] While systems that pour concrete into vertical forms have
been successful in creating decorative patterns on both sides of
the vertical concrete panel, the forms used to create such panels
have had several operational problems. For example, the forms are
quite expensive to make because they must be made of a material
that i) won't adhere to the cured concrete, ii) won't deform to a
great extent under the weight of uncured concrete, and iii) is
sufficiently pliable so as to be easily removable from the pattern
created in the cured concrete. Additionally, the forms used to
create the decorative pattern in the panels are exposed to, and
must be able to withstand, severe environmental conditions such as
frequent cyclical loading between concrete pours, rough handling
during cured concrete removal, and caustic chemical reactions of
curing concrete.
[0007] These environmental conditions have caused liners used in
vertical concrete forms to prematurely degrade and/or become
prematurely separated from adjacent supporting framework structure.
Consequently, the relatively expensive liners have had a relatively
short useful life and it has been necessary to produce new forms on
a relatively frequent basis. Such problems have increased both the
material costs associated with vertical pour systems, and with the
number of labor hours necessary to maintain a constant fabrication
cycle.
SUMMARY OF THE INVENTION
[0008] It has been recognized that it would be advantageous to
develop forms for use in vertically forming concrete panels that
include liner systems that are physically robust and that can
withstand the severe environmental conditions involved in
vertically forming concrete panels.
[0009] The invention provides a form for creating a pattern in
uncured concrete during a casting process, including a support
frame, and a perforated reinforcing structure, coupled adjacent to
at least a portion of the support frame. The perforated reinforcing
structure can have a plurality of apertures defined therein. A
pliable liner can be disposed at least partially within the
plurality of apertures and also about the perforated reinforcing
structure adjacent the support structure. The pliable liner can
have a patterned surface formed thereon for creating a
corresponding pattern in uncured concrete poured adjacent the
form.
[0010] In accordance with another aspect of the invention, a form
system for creating a pattern in uncured concrete during a concrete
casting process is provided including a base, and a pair of
opposing end wall forms that extend upward from the base and
defining end wall surfaces of a vertical mold cavity for uncured
concrete. A pair of opposing side wall forms can extend upward from
the base and can define side wall surfaces of the vertical mold
cavity. Each of the opposing side wall forms can include a
perforated reinforcing structure having a plurality of apertures
defined therein, and a pliable liner, disposed at least partially
within the plurality of apertures and about the perforated
reinforcing structure. The pliable liner can have a patterned
surface formed thereon for creating a corresponding pattern in
uncured concrete poured adjacent the form.
[0011] The present invention also provides for a method for making
a form for vertically molding concrete including positioning a
support frame to support a form. A perforated reinforcing structure
that can have a plurality of apertures disposed thereon can be
coupled to at least a portion of the support frame. A pliable liner
can be disposed at least partially within the plurality of
apertures. The pliable liner can also be disposed about the
perforated reinforcing structure and the support frame. A patterned
surface can be created on the pliable liner in order to form a
corresponding pattern into uncured concrete poured adjacent the
form.
[0012] Additional features and advantages of the invention will be
apparent from the detailed description which follows, taken in
conjunction with the accompanying drawings, which together
illustrate, by way of example, features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of a vertical concrete panel
form in accordance with an embodiment of the invention;
[0014] FIG. 2 is a front, partially sectioned view of the vertical
concrete panel form of FIG. 1;
[0015] FIG. 3 is a sectional view of the vertical concrete panel
form of FIG. 2, taken along section 3-3 of FIG. 2;
[0016] FIG. 4 is perspective view of a vertical concrete panel form
system in accordance with an embodiment of the present invention,
shown in a partially assembled configuration; and
[0017] FIG. 5 is a perspective view of the vertical concrete panel
form system of FIG. 4, shown in an assembled configuration.
DETAILED DESCRIPTION
[0018] Reference will now be made to the exemplary embodiments
illustrated in the drawings, and specific language will be used
herein to describe the same. It will nevertheless be understood
that no limitation of the scope of the invention is thereby
intended. Alterations and further modifications of the inventive
features illustrated herein, and additional applications of the
principles of the inventions as illustrated herein, which would
occur to one skilled in the relevant art and having possession of
this disclosure, are to be considered within the scope of the
invention.
[0019] Illustrated in FIG. 1 is an example of a form, shown
generally at 10, for creating a pattern in uncured concrete during
a casting process in accordance with one aspect of the invention
described herein. As discussed in greater detail below, the form 10
can be used in conjunction with other forms, such as end wall forms
and retaining structure, to form concrete panels (e.g., 11 in FIG.
4) that can be used in vertical applications such as fences,
retaining walls, and the like. One exemplary system with which the
form 10 can be used is described in U.S. Patent Application
Publication No. 20050067551, filed Sep. 30, 2003, which is hereby
incorporated herein in its entirety.
[0020] Vertical concrete panels 11 created by the form 10 of the
present invention are used in a variety of applications, including
residential and commercial fencing, sound wall applications, etc.
Additionally, concrete panels formed in accordance with the present
invention generally require little or no maintenance, provide
superior strength, and can be relatively quickly assembled on the
job site into a fence or other structure. Assembly of the panels
into a fence structure is generally accomplished by installing or
forming posts (not shown) which include slot structure into which
the panels are disposed and held securely.
[0021] The form 10 can mold a decorative pattern into sides of the
concrete panels 11 to give the concrete panels an aesthetically
pleasing appearance such as a rock wall, a brick wall, or other
such desirable patterns. As used herein, the term "decorative
pattern" is understood to mean a pattern applied to the concrete
panels, and may be decorative or functional, or both, in nature. In
addition to the decorative pattern applied to the panel, the
concrete panel can be stained or dyed in a particular color scheme
to enhance the aesthetically pleasing appearance of the panel. In
some embodiments, the term "decorative pattern" can refer to a
smooth, relatively featureless pattern that is decorative in
nature.
[0022] As illustrated in FIGS. 2-3, the form 10 can include a
support frame 12. The support frame 12 can be a structurally
significant material, such as metal, and can be sized and shaped to
support loading from uncured concrete poured within a mold system
as described below. In one aspect, the support frame 12 can be
formed substantially of a plurality of elongate, tubular members 13
that can be welded or otherwise coupled to one another into an
integral frame. In one embodiment, the support frame 12 can also be
formed of relatively flat, sheet-like materials such as reinforced
plywood sheets, metal sheeting, etc. The support frame can be
configured in a variety of manners to ensure that sufficient
support is provided to allow attachment of a liner (discussed in
more detail below) to the support frame. The form 10 can also
include a perforated reinforcing structure 14. The perforated
reinforcing structure 14 can be coupled adjacent to at least a
portion of the support frame 12. The perforated structure can
include a plurality of apertures 16 defined therein. The apertures
can take a variety of forms, and can include a variety of cross
sectional shapes, such as square-shaped, circular, diamond-shaped,
etc. Also, the apertures can be spaced from one another and arrayed
across the reinforcing structure in a variety of manners and
spatial relationships, in both regular, repeating patterns, and in
random patterns.
[0023] The apertures 16 can be holes 18 that extend through the
perforated reinforcing structure 14 and form the perforations in
the reinforcing structure. In one aspect, the perforated
reinforcing structure 14 can be a sheet of expanded metal. As is
known in the art of metal manufacturing, expanded metal is a
product generally formed from a single sheet of metal which is cut
or slit and stretched to "expand" the slits into diamond-shaped
perforations in the metal sheet. A series of "knuckles" are formed
at the edges of each of the perforations as a result of the
stretching and serve to distribute loads applied to the metal
throughout the sheet. The expanded metal can be formed from a
variety of materials, such as steel, stainless steels, brass,
aluminum, etc. As expanded metal can be relatively easily
manufactured and obtained at a relatively low cost, it has been
found to an effective reinforcing structure for liner 20 (discussed
in more detail below). Also, as the expanded metal can be easily
tack-welded or otherwise attached to the support frame (e.g.,
stapled in the case where the support frame includes wood), it can
be easily and securely attached to the support frame.
[0024] As discussed above, the form 10 can also include a pliable
liner 20 that can be disposed at least partially within the
plurality of apertures 16. The pliable liner 20 can also be
disposed at least partially about the perforated reinforcing
structure 14 adjacent the support structure 12. The pliable liner
20 can include a compliant polymer material, such as polyurethane
or 2070 SX polymer. In one aspect of the invention, the pliable
liner is applied about the reinforcing structure adjacent the
support frame while in an uncured, liquid state. As the liquid
fills between and around each of the perforations or apertures 16
when applied adjacent the support frame, an excellent bond is
achieved between the liner and the perforated reinforcing structure
(and between the liner and the support structure). In this
embodiment of the invention, the pliable liner substantially
encompasses the perforated reinforcing structure.
[0025] As the perforated reinforcing structure 14 can be
independently attached to the support frame 12, the reinforcing
structure aids in retaining the liner 20 securely attached to the
support frame so that repeated casting and tear-down cycles can be
achieved without requiring that the liner be frequently replaced.
It has been found that the present invention can produce a form
that is capable of sustaining up to 1,000 casting cycles before
requiring that the liner be replaced or discarded. As the liner
need not be replaced at frequent intervals, a higher quality
polymer, which is generally more expensive than lower quality
materials, can be used to provide a superior finish to the concrete
panels without significantly increasing the cost of each concrete
panel.
[0026] The pliable liner 20 can also be sufficiently stiff to mold
uncured concrete into a decorative pattern. The pliable liner can
also be flexible to allow the form 10 to flex when being assembled
into a form system, as described below. Advantageously, the
flexibility of the pliable liner can extend the usable life of the
form 10 since the form can flex instead of breaking during rough
handling of the form when during assembly and disassembly
procedures.
[0027] Advantageously, the support frame 12 and perforated
reinforcing structure 14 can minimize the amount of compliant
polymer that is needed, such that sufficient polymer is present to
seal the mold cavity, but is prevented from deforming to an
undesirable level by the reinforcing structure. In addition to the
embodiment shown, the reinforcing structure can be disposed on,
over, or adjacent to the support gasket to provide reinforcement to
the support gasket.
[0028] The perforated reinforcing structure can also be formed of
perforated metal, woven wire sheets, welded mesh sheets, and the
like. As such materials can be relatively easily obtained and cut
to preferred sizes, they have been found suitable as reinforcing
structure. In addition, conventional sheet material can also be
utilized, with perforations formed in the sheet material in a
variety of manners, such as drilling, punching, etc.
[0029] The pliable liner 20 can have a patterned surface 22 formed
thereon. The patterned surface can be an inverse decorative pattern
that can form a corresponding decorative pattern on a surface of a
cast concrete wall. Specifically, the patterned surface 22 can
create a corresponding pattern in uncured concrete poured adjacent
the form 10 when the form is used in a form system as described
below. The inverse decorative pattern 22 can be of a variety of
inverse patterns, including brick, rock, or other pseudo structure
that provides the concrete panel with a decorative or functional
advantage.
[0030] The inverse decorative pattern 22 can be formed on or in the
form 10 by a number of methods. In one aspect, the inverse
decorative pattern 22 is provided on the form 10 by application of
the pliable liner 20 to the form 10. The pliable liner 20 can be
formed by preparing a "master" form in which the support frame and
reinforcing structure can be disposed. An uncured polymer can be
poured over the support frame, reinforcing structure and master
form. The uncured polymer can flow around and through the support
frame and the apertures or perforations in the perforated
reinforcing structure. When the viscous polymer cures, the
resulting pliable liner can be removed from the master form and
will be bonded or cured around the reinforcing structure. Once
prepared, the form 10 can be used numerous times to apply the
decorative pattern to a number of concrete panels poured in
cavities at least partially defined by the forms 10. By preparing
many such forms 10 from the same master form, multiple panels
having identical surfaces can be concurrently formed.
[0031] Thus, in use, as wet concrete is poured adjacent the form
10, the weight of the wet concrete ensures that the concrete fills
in and around the textured surface of the inverse decorative
pattern 22. After cure of the concrete, the textured surface
appears in the cured concrete panel as a decorative pattern, such
as a brick wall appearance, a rock wall appearance, etc.
[0032] The form 10 of the present invention can also be utilized to
form concrete panels of a variety of sizes. For example, forms can
be sized to create concrete panels with a length of 12 feet, a
height of 6 or 8 feet, and a thickness of 4 inches. As described in
more detail below, the forms can be used in a form system to create
panels of varied width, including panels with 4, 5 or 6 inch
widths. The forms can be adapted to fit into form systems that can
create a number of variously sized and shaped vertical concrete
panels with minimal adjustments to the form system being necessary
to effectuate formation of differently sized panels.
[0033] Referring now to FIG. 4, a form system, shown generally at
100 is shown with a pair of forms 10 at least partially forming a
mold cavity for creating a pattern in uncured concrete during a
concrete casting process in accordance with the present invention.
The form system 100 can have a base 130 that is disposable on a
support surface, such as the ground or a casting floor. The form
system 100 can also have a pair of opposing end wall forms 140 that
each extend upward from the base 130 and define end wall surfaces
142 of a vertical mold cavity (150 in FIG. 5) for uncured concrete.
The end wall forms 140 can have a perforated reinforcing structure
144 with a plurality of apertures (not shown). A pliable liner 148
can be disposed at least partially within the plurality of
apertures, and about the perforated reinforcing structure 144.
[0034] A pair of forms 10, described above, can define opposing
side wall forms 110 that extend upward from the base 130. The side
wall forms 110 can define side wall surfaces 112 of the vertical
mold cavity. The side wall forms 110 can be spaced a desired
distance apart, corresponding to a desired thickness of the
concrete panel to be formed. As described above, each form 10 can
have a perforated reinforcing structure 14 having a plurality of
apertures (not shown) and a pliable liner 20 disposed at least
partially within, or through the plurality of apertures and about
the perforated reinforcing structure 14. The pliable liner 20 can
have a patterned surface 22 formed thereon for creating a
corresponding pattern in uncured concrete poured adjacent the forms
10.
[0035] The form system 100 can also have a lower support gasket 160
disposable over the base 130 to at least partially define a bottom
surface 162 of the vertical mold cavity. The lower support gasket
can have a perforated reinforcing structure 164 with a plurality of
apertures (not shown). A pliable liner 168 can be disposed at least
partially within the plurality of apertures, and about the
perforated reinforcing structure 164.
[0036] Together the end wall forms 140, the side wall forms 110,
and the lower support gasket 160 can be operably positionable to
form a tetragonal mold cavity 150, as best seen in FIG. 5. The
vertical mold cavity 150 can correspond to a substantially vertical
concrete panel. In one aspect, the tetragonal vertical mold cavity
150 can have a smaller rectangular cross section across a top
surface 152, and a larger rectangular cross section across a front
surface 154.
[0037] Advantageously, the compliant polymer of the pliable liners
20, 148 and 168 can provide an effective seal between the lower
support gasket 160, and each of the end wall forms 140 and side
wall forms 110. As the mold cavity 150 fills with wet concrete, the
various forms are allowed to slightly bend outwardly to form a seal
that increases in effectiveness with the addition of more wet
concrete. Thus, wet concrete can be held within the mold cavity 150
even when larger panels are poured that may generally require
greater amounts of wet concrete.
[0038] Referring to FIG. 5, the form system 100 can also have
securing structure, shown generally at 170, associated with the end
wall forms 140 and the side wall forms 110 that retains and secures
the end wall forms 140 and the side wall forms 110 in the
tetragonal mold cavity configuration in order to receive concrete
in an uncured state within the vertical mold cavity 150. The
securing structure 170 can include various tensioning and
restraining devices, as known in the art, to ensure that the mold
forms are not displaced by the introduction of uncured, or "wet"
concrete in the mold cavity. Once each mold cavity is defined, and
any retaining or securing structure 170 has been applied, wet
concrete can be poured into each mold cavity. Vibrators or other
agitating devices can be utilized when pouring the wet concrete to
minimize voids and ensure the wet concrete fills each cavity to the
extent desired.
[0039] Thus, the mold cavity 150 can be defined by moveable
concrete forms restrained by the securing structure 170 in order to
maintain the vertical mold cavity 150. As an example of the present
invention in use, first side wall form 110 can be positioned in a
desired location within the securing structure 15. Lower support
gasket 160 can be positioned adjacent the side wall form 110,
abutting against the side wall form 110. End wall form 140 can then
be placed within the securing structure associated with side wall
form 110. A second side wall form 110 can then be moved into
position such that end wall form 140 is oriented within the
securing structure 170 associated with the second side wall form
110. In this manner, the end wall form 140 is secured in place
between the side wall forms 110 by the securing structure 170.
[0040] If desired, additional side wall forms 110 can be similarly
positioned with end wall form 140 and lower support gaskets 160
forming ends and a bottom, respectively, of a vertical mold cavity
150. The width of the concrete panels thus formed can be easily
altered by the use of alternate end wall forms and lower support
gaskets. If a wider panel is required, wider end wall forms and
support gaskets can be utilized. If a panel with a narrower width
is required, narrower end wall forms and support gaskets can be
used.
[0041] Once each end wall form 140, side wall form 110 and lower
support gasket 160 are positioned, the forms can be restrained in
position in a number of manners. Due to the substantial weight of
uncured concrete, the various forms will tend to move outwardly
from the defined mold cavity upon introduction of wet concrete into
the cavity. As discussed above, end wall forms 140 can be secured
in place by securing structure 170. Further, as illustrated in FIG.
5, side wall tensioning members 240 can be coupled to the various
side wall forms 110 to restrain the side wall forms from moving in
reaction to forces introduced by wet concrete poured in the mold
cavity.
[0042] The tensioning members 240 can be a variety of those known
in the art, and can include threaded end 242 which can be secured
in place by nut 244. An opposing threaded end 246 can similarly be
secured by nut 248. Each of the nuts 244, 248 can be tightened to
tension the side wall forms together. To provide for variation in
the number of mold cavities formed, threaded end 246 can include a
length of threads that allow nut 248 to be attached in a variety of
positions to facilitate tensioning of a varying number of concrete
forms.
[0043] The tensioning members 240 can be disposed outside of the
mold cavity so as to retain the side wall forms in position without
displacing the wet concrete in the mold cavity. In this manner, the
forms are securely held in position without adversely affecting the
finished panel by introducing foreign matter into the wet concrete
and without leaving cavities in the concrete, as has been done in
previous methods. In this manner, the concrete forms are maintained
securely in place prior to curing of the concrete without
compromising either the structural integrity or aesthetic
appearance of the finished concrete panel.
[0044] Thus, in use, as wet concrete is poured into the mold cavity
150 and adjacent the forms 10, the weight of the wet concrete
ensures that the concrete fills in and around the patterned surface
of the inverse decorative pattern 22. After cure, the inverse of
the patterned surface 22 appears in the cured concrete panel as a
decorative pattern, such as a brick wall appearance, a rock wall
appearance, etc. Because the present invention advantageously forms
concrete panels in a vertical orientation, the wet concrete can
fill the textured surface of inverse decorative patterns on both
sides of the mold cavity 150 equally well, in contrast to
horizontal mold systems which can generally only apply a
well-defined pattern to a lower surface of the concrete panel.
[0045] After pouring, the wet concrete in the form system 100 can
be allowed to cure, after which the various retaining structure and
forms can be removed. The cured panel can then be removed, and the
process can be repeated a number of times to create a number of
concrete panels. In the case where the proper concrete mix is used,
the system can form panels on a one day cycle, that is, panel can
be poured in the morning and allowed to cure through the night. The
following morning, the cured panel can be removed, the forms can be
reassembled, and the process begun again.
[0046] The present invention also provides for a method for making
a form for vertically molding concrete including positioning a
support frame to support a form. A perforated reinforcing structure
having a plurality of apertures disposed thereon can be coupled to
at least a portion of the support frame. The perforated reinforcing
structure can include a substantially planar sheet of expanded
metal. A pliable liner can be disposed at least partially within
the plurality of apertures. The pliable liner can also be disposed
about the perforated reinforcing structure and the support frame. A
patterned surface can be created on the pliable liner in order to
form a corresponding pattern into uncured concrete poured adjacent
the form. The pliable liner can be a compliant polymer that can be
poured into the plurality of apertures and about the perforated
reinforcing structure and support frame. The compliant polymer of
the pliable liner can be cured to form a mold surface for retaining
uncured concrete.
[0047] It is to be understood that the above-referenced
arrangements are illustrative of the application for the principles
of the present invention. Numerous modifications and alternative
arrangements can be devised without departing from the spirit and
scope of the present invention while the present invention has been
shown in the drawings and described above in connection with the
exemplary embodiments(s) of the invention. It will be apparent to
those of ordinary skill in the art that numerous modifications can
be made without departing from the principles and concepts of the
invention as set forth in the claims.
* * * * *