U.S. patent application number 14/164704 was filed with the patent office on 2014-05-22 for overlapping formliner manufacturing process.
This patent application is currently assigned to ARCHITECTURAL POLYMERS, INC.. The applicant listed for this patent is ARCHITECTURAL POLYMERS, INC.. Invention is credited to Richard E. FASCHING, Marshall Gilbert WALTERS.
Application Number | 20140138878 14/164704 |
Document ID | / |
Family ID | 42264624 |
Filed Date | 2014-05-22 |
United States Patent
Application |
20140138878 |
Kind Code |
A1 |
WALTERS; Marshall Gilbert ;
et al. |
May 22, 2014 |
OVERLAPPING FORMLINER MANUFACTURING PROCESS
Abstract
A process of manufacturing an overlapping formliner is
disclosed. The process includes applying a formliner material to a
mold, the mold having pocket molds for producing formliner pockets
and a lattice of ridge molds for producing formliner ridges, then
forming the overlapping formliner, the overlapping formliner having
a varied ridge width being configured to be positioned to overlap
an adjacent formliner, and then demolding the formliner from the
mold to produce the formliner having the formliner pockets and the
formliner ridges.
Inventors: |
WALTERS; Marshall Gilbert;
(Leighton, PA) ; FASCHING; Richard E.; (Palmerton,
PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ARCHITECTURAL POLYMERS, INC. |
Palmerton |
PA |
US |
|
|
Assignee: |
ARCHITECTURAL POLYMERS,
INC.
Palmerton
PA
|
Family ID: |
42264624 |
Appl. No.: |
14/164704 |
Filed: |
January 27, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12717172 |
Mar 4, 2010 |
8636261 |
|
|
14164704 |
|
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|
|
12253809 |
Oct 17, 2008 |
8181930 |
|
|
12717172 |
|
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|
11099347 |
Apr 5, 2005 |
7871054 |
|
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12253809 |
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60981151 |
Oct 19, 2007 |
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|
60650934 |
Feb 8, 2005 |
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Current U.S.
Class: |
264/322 ;
264/299; 264/328.1; 264/334 |
Current CPC
Class: |
B28B 19/0061 20130101;
E04G 9/10 20130101; E04G 11/20 20130101; E04F 13/0862 20130101;
B29D 99/0014 20130101 |
Class at
Publication: |
264/322 ;
264/328.1; 264/334; 264/299 |
International
Class: |
B29D 99/00 20060101
B29D099/00 |
Claims
1. A process of manufacturing an overlapping formliner, the process
comprising: applying a formliner material to a mold, the mold
having pocket molds for producing formliner pockets and a lattice
of ridge molds for producing formliner ridges; then forming the
overlapping formliner, the overlapping formliner having a varied
ridge width being configured to be positioned to overlap an
adjacent formliner; and then demolding the formliner from the mold
to produce the formliner having the formliner pockets and the
formliner ridges.
2. The process of claim 1, wherein the mold includes a rigid
high-density urethane closed cell foam.
3. The process of claim 1, wherein the mold includes a rigid
polyisocyanurate foam.
4. The process of claim 1, wherein the overlapping formliner
includes an interface to be positioned between the overlapping
formliner and the adjacent formliner and reduce leakage of
cementitious material.
5. The process of claim 1, wherein the overlapping formliner
includes alignment features.
6. The process of claim 5, wherein the alignment features are
within the varied ridge width.
7. The process of claim 5, wherein the alignment features provide
additional stability during stacking for transport.
8. The process of claim 1, wherein the overlapping formliner
includes alignment features on two sides.
9. The process of claim 1, wherein the overlapping formliner
includes alignment features on four sides.
10. The process of claim 1, wherein the overlapping formliner and
the adjacent formliner are substantially identical.
11. The process of claim 1, wherein the overlapping formliner and
the adjacent formliner are substantially different.
12. The process of claim 1, wherein the formliner material includes
an elastomeric material.
13. The process of claim 1, wherein the formliner material includes
a recycled material.
14. The process of claim 1, wherein the applying of the formliner
material includes injecting the formliner material into the
mold.
15. The process of claim 1, wherein the applying of the formliner
material includes pouring the formliner material into the mold.
16. The process of claim 1, wherein the forming of the overlapping
formliner is by injection molding.
17. The process of claim 1, wherein the forming of the overlapping
formliner is by thermoforming.
18. The process of claim 1, wherein the mold has pores and the
formliner materials does not seep into pores of the mold and bond
to the mold.
19. A process of manufacturing an overlapping formliner, the
process comprising: injecting or pouring an elastomeric material
into a rigid high-density urethane closed cell foam or a rigid
polyisocyanurate foam mold having a pocket mold for producing
formliner pockets and a lattice of ridge molds for producing
formliner ridges; then forming the overlapping formliner, the
overlapping formliner having a varied ridge width being configured
to be positioned to overlap an adjacent formliner; and then
demolding the overlapping formliner to produce the formliner having
the formliner pockets and the formliner ridges.
20. A process of manufacturing a formliner, the process comprising:
applying a formliner material to a mold, the mold having a pocket
mold for producing formliner pockets and a lattice of ridge molds
for producing formliner ridges; then forming the overlapping
formliner, the overlapping formliner having a varied ridge width
being configured to be positioned to overlap an adjacent formliner;
and then demolding the formliner from the mold to produce the
formliner having the formliner pockets and the formliner ridges;
wherein the mold includes a rigid high-density urethane closed cell
foam or a rigid polyisocyanurate foam.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 12/717,172, entitled Variable Angle
Formliner filed Mar. 4, 2010, with an issue date of Jan. 28, 2014
as U.S. Pat. No. 8,636,261, both of which claim priority to and the
benefit of U.S. patent application Ser. No. 12/253,809, entitled
Variable Angle Formliner, filed Oct. 17, 2008, which issued as U.S.
Pat. No. 8,181,930 on May 22, 2012, both of which claim priority to
U.S. Provisional Patent Application No. 60/981,151, filed Oct. 19,
2007, and U.S. patent application Ser. No. 11/099,347, entitled
Formliner Apparatus, filed Apr. 5, 2005, which issued as U.S. Pat.
No. 7,871,054 on Jan. 18, 2011, both of which claim priority to
U.S. Provisional Patent Application No. 60/650,934, filed Feb. 8,
2005, all of which are hereby incorporated by reference in their
entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to manufacturing
formliners. Specifically, the present disclosure relates to
manufacturing overlapping formliners.
BACKGROUND OF THE DISCLOSURE
[0003] Architectural designs for various types of construction,
including buildings and bridges, call for the use of brick in the
construction of walls. Although ordinarily of little structural
importance in modern construction projects, brick walls continue to
be used for decorative architectural purposes. However, making
walls entirely of brick and mortar has become relatively expensive
in recent years in comparison to poured concrete. One development
that has reduced the cost of brick walls has been the use of
decorative thin bricks, which are cast into concrete wall panels.
Such decorative bricks are significantly thinner than normal bricks
and therefore are significantly less expensive than normal bricks
per square foot of wall coverage.
[0004] Making decorative bricks into a regular brick wall can be
difficult or impossible. In order to cast the decorative bricks
into the concrete walls, polymer brick formliners were developed,
which have a plurality of brick-receiving recesses. The
brick-receiving recesses are designed to hold the decorative bricks
in place during the casting of concrete walls. The brick-receiving
recesses are formed into the formliners in regular brick patterns,
with each recess having the same depth, so as to create a clean and
organized brick appearance in the final panel product. Such
formliners are first placed on a surface capable of supporting the
weight of the formliners, decorative bricks, and poured concrete.
Decorative bricks are then placed into the formliners and concrete
is cast on top of the decorative bricks and formliners. After
curing, the formliner is removed, revealing the wall having
decorative bricks separated by cement mortar joints, ready for use
in construction.
[0005] Unfortunately, the clean and organized appearance of the
final brick-lined concrete panel has resulted in an unforeseen
aesthetic problem. The use of such formliners in the manufacture of
buildings has resulted in a very consistent appearance in such
prefabricated wall sections. One purpose that drove the development
of brick formliners was the creation of a wall that had the
appearance of hand-laid brick, without the extra cost associated
with it. However, the regularity and precision of the thin brick
placement, which is the result of the use of current brick
formliners, has resulted in the mass production of brick lined
concrete panels that appear as though they have been manufactured
by a machine rather than built up by hand.
[0006] Furthermore, previous master molds for producing polymer
formliners were made from a very dense material, such as aluminum
or steel. While this makes it easy to remove the formliner from the
master mold during formliner manufacturing, it results in a very
unnatural glass smooth joint when the form liners are used in
combination with brick and cementitious material to produce wall
sections.
[0007] What is needed is a new type of formliner that can be used
to manufacture a brick wall which has the appearance that it was
built by hand, rather than manufactured with a brick formliner.
SUMMARY OF THE DISCLOSURE
[0008] According to an embodiment of the disclosure, a process of
manufacturing an overlapping formliner includes applying a
formliner material to a mold, the mold having pocket molds for
producing formliner pockets and a lattice of ridge molds for
producing formliner ridges, then forming the overlapping formliner,
the overlapping formliner having a varied ridge width being
configured to be positioned to overlap an adjacent formliner, and
then demolding the formliner from the mold to produce the formliner
having the formliner pockets and the formliner ridges.
[0009] According to another embodiment of the disclosure, a process
of manufacturing an overlapping formliner includes injecting or
pouring an elastomeric material into a rigid high-density urethane
closed cell foam or a rigid polyisocyanurate foam mold having a
pocket mold for producing formliner pockets and a lattice of ridge
molds for producing formliner ridges, then forming the overlapping
formliner, the overlapping formliner having a varied ridge width
being configured to be positioned to overlap an adjacent formliner,
and then demolding the overlapping formliner to produce the
formliner having the formliner pockets and the formliner
ridges.
[0010] According to another embodiment of the disclosure, a process
of manufacturing a formliner includes applying a formliner material
to a mold, the mold having a pocket mold for producing formliner
pockets and a lattice of ridge molds for producing formliner
ridges, then forming the overlapping formliner, the overlapping
formliner having a varied ridge width being configured to be
positioned to overlap an adjacent formliner, and then demolding the
formliner from the mold to produce the formliner having the
formliner pockets and the formliner ridges. The mold includes a
rigid high-density urethane closed cell foam or a rigid
polyisocyanurate foam.
[0011] An advantage of an exemplary embodiment of the disclosure is
that the angle of the pockets are varied, providing a brick veneer
wall manufactured with the formliner of the present disclosure with
the appearance of hand laid brick.
[0012] An advantage of another exemplary embodiment of the
disclosure is that the depth of the pockets may also be varied,
further providing a brick veneer wall manufactured with the
formliner of the present disclosure with the appearance of hand
laid brick.
[0013] An advantage of yet another exemplary embodiment of the
disclosure is that the formliner contains a slightly rough texture,
such that mortar joints formed by pouring cementitious material
over the formliner provide a sandy, grout-like appearance.
[0014] Still another advantage of certain embodiments is that
adjacent formliners can be overlapped in a modular manner despite
the non-uniform arrangement resulting from the varying angles and
ridge widths.
[0015] Other features and advantages of the present disclosure will
be apparent from the following more detailed description of the
preferred embodiment, taken in conjunction with the accompanying
drawings which illustrate, by way of example, the principles of the
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 illustrates a front view of a formliner in accordance
with an exemplary embodiment of the disclosure.
[0017] FIG. 2 illustrates a schematic illustration of a front view
of a pocket rotated in an x-y plane.
[0018] FIG. 3 illustrates a front view of a plurality of formliners
according to an exemplary embodiment of the disclosure.
[0019] FIG. 4A illustrates a front view of a plurality of
formliners according to another exemplary embodiment of the
disclosure.
[0020] FIG. 4B illustrates a sectional view of the plurality of
formliners in FIG. 4A along line 4-4.
[0021] FIG. 5A illustrates a front view of a formliner with a
plurality of variable angles.
[0022] FIG. 5B illustrates a perspective view of the formliner in
FIG. 5A.
[0023] FIG. 6A illustrates a perspective view of a master mold
according to an exemplary embodiment of the disclosure.
[0024] FIG. 6B illustrates a sectional view of the master mold in
FIG. 6A along a line 6-6.
[0025] FIG. 7 illustrates a perspective view of an exemplary
formliner.
[0026] FIG. 8 illustrates a perspective view of an exemplary
formliner overlapping an additional formliner to form a larger wall
portion.
[0027] Wherever possible, the same reference numbers will be used
throughout the drawings to represent the same parts.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0028] FIGS. 1, 2, 3, 4A, 4B, 5A, 5B, 7 and 8 illustrate
formliners. As will be appreciated, the illustrations are intended
to provide an understanding of the principles of the formliner in
accordance with exemplary embodiments of the disclosure and are not
necessarily to scale. Similarly, FIGS. 6A and 6B illustrate a
master mold and are intended to provide an understanding of the
principles of the master mold and are not necessarily to scale.
[0029] The formliner 100 may be manufactured from any suitable
material, for instance a resilient polymer of sufficient strength
compatible with a cementitious material. Such a material may
include, but not be limited to, a thermoplastic or elastomeric
material, such as rubber. In one embodiment, formliner 100 is
manufactured from a resilient elastomeric material so that the same
formliner can be re-used. In another embodiment, formliner 100 is
manufactured from an inexpensive, preferably recyclable,
thermoplastic material for a single-use, permitting formliner 100
to be recycled or disposed.
[0030] Referring to FIG. 1, the formliner 100 has a plurality of
courses 120, which may be rows as shown in the running bond pattern
depicted in FIG. 1. Each course 120 has a plurality of recessed
pockets 140 separated by ridges 130. Pockets 140 are sized and
configured to receive decorative thin brick or similar veneer
products, while ridges 130 are sized and configured to separate
pockets 140, such that cementitious material applied over formliner
100 thereby gives the appearance of a mortar joint between the
decorative thin bricks in a completed wall made using the formliner
100. In one embodiment, as shown in FIG. 7, at least one pocket 140
may have rounded corners to receive tumbled brick to further impart
a distressed or aged appearance to a finished wall.
[0031] Referring again to FIG. 1, pockets 140 may be of any size
and may be arranged in any pattern, but generally are sized to
receive standard-size thin bricks and generally are arranged in any
one of several traditional masonry patterns. Exemplary pocket sizes
include pockets 140 sized to receive utility, Norman, modular and
closure thin bricks, by way of example only. Exemplary masonry
patterns include running bond, soldier course, Flemish bond, stack
bond, 1/3 running bond, herringbone, basket weave, offset weave,
and combinations thereof, by way of example only.
[0032] Formliners 100 may be modular in nature, with several
formliners 100 smaller than the actual wall size to be formed
positioned adjacent one another and/or overlapped. It will be
appreciated that some pockets of each formliner may be associated
with pre-determined sub-dimensions of brick. For example, as shown
in FIG. 1, some of pockets 140 are sized to receive full size thin
bricks, while others are half-size bricks to permit continuity of
the brick pattern in the wall to be formed. Where multiple
formliners 100 are positioned adjacent one another to form part of
a wall larger than any single formliner 100 (see, e.g., FIGS. 3,
4A, 4B, 5, 5B, 8), a full size thin brick may be placed in adjacent
half-pockets 140 in the same course 120 of adjacent formliners 100.
Similarly, at the wall's edge, half-sized thin bricks may be placed
in the half-pockets to give the appearance, for example, of the
corner of a masonry wall.
[0033] Referring to FIG. 5B, one or more of the ridges 130 may have
a varied width (the width being measured as shown by width W in
FIG. 5B). The varied width may extend along the ridge 130 through
the entire course 120. In one embodiment, the varied width may
extend along the ridge 130 through a portion of the course 120. For
example, the varied width may extend along a portion of one pocket
140, one pocket 140, two pockets 140, or any other suitable
distance.
[0034] The formliner 100 may be of any desired dimensions to
produce a wall of any size. Alternatively, multiple formliners 100
can be used together to form a wall larger than any single
formliner 100 as previously described by aligning a first edge 150
of a first formliner 100 with a second edge 155 of a second
formliner 100 in any suitable manner, as illustrated for example,
in FIG. 3 showing four modular formliners 100 positioned adjacent
one another. For modular applications, it will be appreciated that
the dimensions of the formliner 100 may be adjusted depending on
the pattern and brick size according to well-known masonry
principles to avoid or reduce the amount of cutting or partial
formliners needed for standard size masonry walls. For example, it
may be advantageous to produce the formliner 100 having dimensions
of 2 feet square, 4 feet square or 4 feet by 8 feet, which permit
standard size walls to easily be prepared.
[0035] The ridges 130 are formed in a lattice that defines lateral
walls between the courses 120 as well as longitudinal sides 510
between the pockets 140 within the same course 120 to separate the
pockets 140 and in order to give the appearance of mortar joints in
the completed wall made using formliner 100. The appearance of the
ridges 130 may be modified by rotating the pockets 140. For
example, the ridges 130 may be narrower or wider in various
portions of formliner 100 when pockets 140 in the same portion of
the formliner 100 are rotated (as best seen in FIGS. 5A and
5B).
[0036] This varying of ridges 130 may be desirable in creating an
aesthetic appearance that the completed section of wall is hand
laid because many hand laid walls rely upon a mortar joint having a
non-uniform appearance, which may include covered or raked
surfaces. Similarly, varying the surface of the ridges 130, for
instance by varying the dimensions (i.e., height or width) or
including an inconsistent texture, may result in the completed
section of wall appearing to be hand laid.
[0037] As schematically illustrated in the front view of the pocket
140 in FIG. 2, each pocket 140 in each course 120 has an angle of
rotation. For the purposes of this application, the phrase "angle
of rotation" refers to the amount by which pocket 140 is rotated
out of any one of an x-y plane, an x-z plane, and a y-z plane. The
x-axis is a line parallel with any course 120; the y-axis is a line
perpendicular to the x-axis; the z-axis is a line perpendicular to
both the x-axis and the y-axis. Thus one or more of the pockets 140
may be rotated so that the bricks within each course and with
respect to adjacent courses are not uniformly aligned when the
finished wall section is viewed.
[0038] The angle of rotation for each pocket 140 may be from about
-5.0.degree. to about 5.0.degree. in each of the three planes.
Preferably, the angle of rotation is in the range of about
-2.0.degree. to about 2.0.degree. and more preferably from about
-1.0.degree. to about 1.0.degree.. The angle by which each pocket
140 is rotated may be random within the range. In one embodiment,
pockets 140 are oriented at one of five different angles of
rotation: -1.0.degree., -0.5.degree., 0.degree., 0.5.degree. and
1.0.degree.. The number of bricks at each angle within the
formliner 100 may be varied randomly or according to a
predetermined pattern, which may be selected, for example, because
the pattern gives the appearance of being random or otherwise
appears non-uniform in a manner that is aesthetically appealing. In
an alternate embodiment, the distribution of the angles of rotation
may be arranged in a predetermined pattern that does not appear
non-uniform or random. In this alternate embodiment, varying angles
may be used for additional aesthetic purposes, such as to create
designs.
[0039] While some or all of the pockets 140 are rotated from level
(i.e., have an angle of rotation other than 0.degree.), each of the
corners of the formliner 100 itself are preferably square to
achieve a better modular fit when multiple formliners are
positioned adjacent one another.
[0040] While FIG. 2 illustrates pocket 140 rotated within the x-y
plane, it is to be understood that the rotation may be within the
x-y plane, the x-z plane, the y-z plane, and/or any combination
thereof
[0041] FIGS. 5A and 5B illustrate formliner 100 with pockets 140
rotated within the x-y plane, the x-z plane, the y-z plane, and
combinations thereof. Rotation of pockets 140 permits a side of
pocket 140 to be partially seen in the front view of FIG. 5A. As
illustrated in FIG. 5A, the side visible depends upon which
direction pocket 140 is rotated. For pockets 140 that are rotated
in multiple directions, multiple sides are visible from the front
view of FIG. 5A. By way of example, pocket 502 is rotated within
the y-z plane thereby permitting the lateral sides 500 of the
pocket to be visible in FIG. 5A. By way of example, pocket 504 is
rotated in the x-z plane thereby permitting the longitudinal sides
510 of the pocket to be visible. By way of example, pocket 506 is
rotated in the x-y plane thereby orienting the pocket so that it is
not parallel along course 120. By way of example, in formliner 100
illustrated in FIGS. 5A and 5B, pockets 508 are rotated in
combinations of directions.
[0042] In some embodiments, such as those in which the formliner is
constructed of a durable, elastomeric material, like formliners may
be butted together in an adjacent manner as illustrated in FIG. 3.
In other embodiments, the formliner may be constructed of a
thermoplastic material for individual use, and consequently may be
constructed of a thinner, less durable material in which adjacent
formliners are positioned adjacent one another in an overlapping
manner for increased support at the interface between formliners
and to reduce leakage of cementitious material. In such cases, the
presence of varying pocket angles and a corresponding variance in
ridge width increases the complexity of how overlapping formliners
can be joined.
[0043] Referring to FIGS. 7 and 8, this complexity is addressed by
providing a first formliner 700 that may be joined with a second
formliner to form a larger wall portion 800 or complete wall by
being joined along a joining portion 702 that may include alignment
features. The alignment features may include overlapping features
706 and/or overlapped features 707. The overlapping features 706
are configured to align with the overlapped features 707 to form a
substantially seamless larger wall portion 800. The overlapping
features 706 may be positioned on a side opposite overlapped
features 707. As shown in FIGS. 7 and 8, overlapping features 706
may be positioned on two sides and overlapped features 707 may be
positioned on the remaining two sides.
[0044] Absent the joining portion 702 for formliners constructed to
be assembled in an overlapping fashion, the varying widths of the
ridges 130 along the joining portion 702 may result in difficulty
in positioning multiple formliners 100 to form the completed wall.
Including the alignment features permits repeatable positioning of
multiple formliners 100 having varying widths of the ridges 130.
Thus, joining portion 702 may permit the desired aesthetic features
of varying widths to be present between multiple formliners 700. As
a result, modular formliners having squared corners can still be
easily formed in a repetitious manner even though the wall segment
formed by any one formliner may not itself be entirely square as a
result of the varying dimensions of the ridges 130 and pocket
angles.
[0045] The modular formliner 700 may be joined to a formliner
similar to formliner 700 (as shown in FIG. 8), and/or any other
suitable formliner. The formliner 700 may include alignment
features for overlapping (or being overlapped by) the second
formliner. The alignment features may be within one or more of the
ridges 130 of the first modular formliner 700. In one embodiment,
the alignment features may provide additional stability and further
consolidation for a plurality of modular formliners 700 to be
stacked for transport.
[0046] In one embodiment, the alignment features are within the
ridge 130 extending along the joining portion 702. In the
embodiment, the ridge 130 of the modular formliner 700 overlaps (or
is overlapped by) a similar ridge of the second formliner to form a
portion of a wall or a completed wall. Additionally or
alternatively, the alignment features may be part of any other
suitable feature of the formliner 700.
[0047] In one embodiment, the joining portion 702 may correspond to
a partial pocket 704 for a pre-determined sub-dimension of a brick.
In another embodiment, as shown in FIG. 8, the joining portion 702
may correspond to the pocket 140, the ridge 130, and the partial
pocket 704. The partial pocket 704 may be configured to receive a
portion of a brick. Including the partial pocket 704 and/or pocket
140 in the joining portion 702 may prevent cementitious material
from seeping through a seam that may be created if two thin,
thermoplastic formliners were aligned without overlapping. Also,
the predetermined sub-dimension of the brick may prevent the
formation of a visible seam in the portion of the wall or the
completed wall.
[0048] The formliner 700 may include a plurality of portions
capable of being joined. For example, the formliner 700 of FIG. 7
may be joined to a formliner identical to the formliner 700 to
extend the overlapping formliners in the Y direction to form the
larger wall portion 800 (in addition to the position for stacking
modular formliners 700). As seen in FIG. 8, one formliner 700
includes an overlapping portion 802 covered by the joining portion
702 of the other modular formliner 700. Similarly, the formliner
700 of FIG. 7 may be joined to a formliner identical to the
formliner 700 to extend the formed portion 800 in the X direction.
As will be appreciated, multiple modular formliners 700 may be
overlapped in varying configurations to achieve the desired size
for the larger wall portion 800.
[0049] According to another embodiment of the disclosure, the depth
of the pocket may also be varied, as described, for example, in
U.S. Publication 2006/0091282, which is hereby incorporated by
reference in its entirety. This varying depth may be combined with
the varying angles according to the exemplary embodiments of the
present disclosure.
[0050] Referring to FIGS. 4A and 4B, the varying depths combined
with varying angles of rotation may be utilized to further enhance
the realistic appearance of a wall produced by formliner 100. As
illustrated, each pocket 140 has a bottom surface that is a plane
at one of three different depths, .alpha., .beta., .gamma., in
which the different depths are illustrated with different
cross-hatchings. The .alpha. pockets have a first predetermined
depth, as measured from any suitable plane of reference. In one
embodiment, the reference plane is the plane encompassing the
highest point of ridges 130 (i.e., the apex of the ridge for a
covered joint or the top plane of the ridge for a raked joint). The
.beta. pocket has a second predetermined depth, which in the
illustrated embodiment is 3/16 in. less than the .alpha. pockets.
Similarly, in the illustrated embodiment, the .gamma. pockets have
a third predetermined depth 3/8 in. less than the .alpha. pockets
(and, thus, 3/16 in. less than the .beta. pockets).
[0051] Where multiple pocket depths are employed, the number of
different pocket depths may be as few as two and as great as the
number of pockets 140 in formliner 100. In embodiments in which the
pocket depths are varied, the difference in pocket depths may vary
from about 0.01 in. to about 0.25 in., and more typically may vary
from about 1/16 in. to about 3/8 in. Like the distribution of the
angles of rotation, the distribution of pocket depths within
formliner 100 may be substantially random. In other embodiments,
the distribution of pocket depths may be arranged in a
predetermined pattern, which may be selected, for example, because
it gives the appearance of being random or otherwise gives the
appearance of being non-uniform in a manner that is aesthetically
appealing. It will be appreciated that pockets may be random within
a formliner but identical to pockets in an identical formliner. In
an alternate embodiment, the distribution of pocket depths may be
arranged in a predetermined pattern that does not appear
non-uniform or random. In this alternate embodiment, varying depths
may be used for aesthetic purposes, such as to create designs.
[0052] FIGS. 6A and 6B illustrate a master mold 600, according to
one exemplary embodiment of the disclosure, for producing
formliners 100. Master mold 600 may be used independently or in
conjunction with other master molds to produce a larger
formliner.
[0053] The manufacturing process to produce formliners 100
generally involves production from master mold 600. The material
for formliner 100 is injected or poured into master mold 600 and is
formed using well-known injection molding, thermoforming, or rubber
casting techniques. Master mold 600 may be aluminum, steel or other
high density material. Each master mold 600 includes pocket molds
640 that produce pockets 140 and a lattice of ridge molds 630 that
produces ridges 130 in the formliner. As will be appreciated by
those skilled in the art, producing varying angle or depth pockets
140 in a formliner may be achieved by using pocket molds 640 with
corresponding varying angles or heights and ridge molds 630 with
varying angles or depths.
[0054] In a preferred embodiment, master mold 600 is a rigid foam,
such as a rigid high-density urethane closed cell foam or a rigid
polyisocyanurate foam. A master mold 600 formed from such rigid
foams produces a textured formliner 100 having textured ridges 130
that results in a more realistic mortar joint that is sandy and
grout-like in feel and appearance. The results can be achieved with
ridges 130 that provide a mortar joint having either a covered
(rounded) or raked (flat) profile. Generally, liquid molding
compounds used in manufacturing elastomeric liners are difficult to
remove from porous master molds, as the compound may seep into the
pores and bond with the master mold. As a result, demolding can
destroy the master mold and damage the formliner beyond reasonable
repair. The rigid urethane and polyisocyanurate closed cell foams
are unexpectedly able to resist destruction during the demolding
process, while repeatedly providing a formliner capable of
achieving the desired realistic result.
[0055] While the disclosure has been described with reference to a
preferred embodiment, it will be understood by those skilled in the
art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the disclosure. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
disclosure without departing from the essential scope thereof.
Therefore, it is intended that the disclosure not be limited to the
particular embodiment disclosed as the best mode contemplated for
carrying out this disclosure, but that the disclosure will include
all embodiments falling within the scope of the appended
claims.
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