A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised
A formliner, sheet, system, and methods of use and manufacture are provided in order to provide a product that can minimize and/or eliminate visible seaming between interconnected formliners during fabrication of a pattern on a curable material. In some embodiments, the formliner can comprise raised sections that define interrelated inner and outer dimensions. Thus, a plurality of formliners can be interconnected by overlaying raised sections thereof. Further, the formliner can comprise one or more detents and one or more protrusions to enable engagement between interconnected formliners without requiring adhesives. In this manner, formliners can be interconnected in a nested manner such that visible seaming between the interconnected formliners is reduced and/or eliminated.
대표청구항▼
1. Formliners comprising at least two formliners configured to form a corner in curable material when the at least two formliners are assembled together, the formliners comprising: a first formliner comprising: a cell comprising a recessed portion, wherein at least a part of the recessed portion is
1. Formliners comprising at least two formliners configured to form a corner in curable material when the at least two formliners are assembled together, the formliners comprising: a first formliner comprising: a cell comprising a recessed portion, wherein at least a part of the recessed portion is configured contact the curable material;a boundary side extending along at least a part of the cell of the first formliner, the boundary side connected to the cell at a predetermined angle relative to the recessed portion of the cell of the first formliner, the predetermined angle corresponding to a desired angle of the corner when forming the corner in the curable material; anda rib extending along at least a part of the cell of the first formliner toward the boundary side, the rib of the first formliner comprising an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material; anda second formliner comprising: a cell comprising a recessed portion; anda rib extending along at least a part of the cell of the second formliner, the rib of the second formliner comprising an opening having a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner when the second formliner is positioned at the predetermined angle relative to the first formliner,wherein the first formliner is configured to be assembled with the second formliner at the predetermined angle to form the corner in the curable material with the desired angle by mating the opening of the rib of the second formliner with exterior surface of the rib of the first formliner with the boundary side of the first formliner contacting the recessed portion of the cell of the second formliner along the predetermined angle relative to the recessed portion of the cell of the first formliner to minimize visible seams in the curable material. 2. The formliners of claim 1, wherein the opening comprises a recess formed in the rib of the second formliner, the recess comprising an interior surface, wherein the exterior surface of the rib of the first formliner is configured to nest within the recess by directly contacting the interior surface of the recess to form a tight fit between the first and second formliners when the first and second formliners are assembled at the predetermined angle. 3. The formliners of claim 2, wherein the second formliner further comprises a mating ledge, the mating ledge connected to the recessed portion of the cell of the second formliner, wherein, to facilitate alignment of the first and second formliners when the first and second formliners are being assembled, the mating ledge extends along at least a part of the recessed portion of the cell of the first formliner when the first and second formliners are assembled. 4. The formliners of claim 3, wherein the first formliner further comprises a ledge recess formed along at least a part of the boundary side, the ledge recess comprising a reduced geometry in the first formliner corresponding to the mating ledge such that the mating ledge is received into the ledge recess to facilitate alignment of the first and second formliners when the first and second formliners are being assembled. 5. The formliners of claim 3, wherein the mating ledge is connected to the rib of the second formliner proximate to the interior surface to rigidly attach to the second formliner at the predetermined angle relative to the recessed portion of the cell of the second formliner. 6. The formliners of claim 3, wherein at least a portion of the mating ledge is movable relative the recessed portion of the cell of the second formliner such that an angle between the mating ledge and the recessed portion of the cell of the second formliner is adjustable. 7. The formliners of claim 6, wherein the recessed portion of the cell of the second formliner and the mating ledge are formed from a monolithic piece of material, wherein the monolithic piece of material comprises slits between the mating ledge and the rib of the second formliner to allow adjustment of the angle between the mating ledge and the recessed portion of the cell of the second formliner. 8. The formliners of claim 1, wherein the opening of the rib of the second formliner comprises an edge extending along the cross-sectional profile of the rib of the second formliner, the edge extending from the recessed portion of the cell of the second formliner. 9. The formliners of claim 8, wherein the edge is adjustable to enlarge the opening of the rib of the second formliner depending on the predetermined angle between the boundary side and the recessed portion of the cell of the first formliner. 10. The formliners of claim 9, wherein the edge comprises tear-away portions connected to the rib of the second formliner, the tear-away portions configured to be detached from the rib of the second formliner to enlarge the opening of the rib of the second formliner. 11. The formliners of claim 1, wherein the first formliner further comprises a detent between the cell and the rib of the first formliner, the detent extending away from the recessed portion of the cell of the first formliner, wherein the second formliner further comprises a protrusion connected to the rib at the opening of the rib of the second formliner, the protrusion extending into the opening of the rib of the second formliner, and wherein the protrusion of the second formliner engages the detent of the first formliner to securely assemble the first and second formliners together. 12. The formliners of claim 1, wherein the predetermined angle is substantially a right angle corresponding to the desired angle of the corner in the curable material being a right angle. 13. Formliners comprising at least two formliners configured to form a corner in curable material when the at least two formliners are assembled together, the formliners comprising: a first formliner comprising: a cell; anda rib extending along at least a part of the cell of the first formliner, the rib of the first formliner comprising an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material; anda second formliner comprising: a cell comprising a recessed side;a flange connected to the recessed side of the cell of the second formliner; anda rib extending along at least a part of the cell of the second formliner, the rib of the second formliner comprising an opening having a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner when the second formliner is positioned at a predetermined angle relative to the first formliner, the predetermined angle corresponding to a desired angle of the corner when forming the corner in the curable material,wherein the first formliner is configured to be assembled with the second formliner at the predetermined angle to form the corner in the curable material with the desired angle by overlaying the opening of the second formliner onto the rib of the first formliner to minimize visible seams in the curable material at the corner, andwherein, when the first and second formliners are assembled, the flange extends along at least a part of the recessed side of the cell of the first formliner to facilitate alignment of the first and second formliners. 14. The formliners of claim 13, wherein the first formliner further comprises a ledge recess formed along at least a part of an edge of the first formliner, the ledge recess comprising a reduced geometry in the first formliner corresponding to the flange such that the flange is received into the ledge recess to facilitate alignment of the first and second formliners when the first and second formliners are being assembled. 15. The formliners of claim 13, wherein at least a portion of the flange is movable relative the recessed side of the cell of the second formliner such that an angle between the flange and the recessed side of the cell of the second formliner is adjustable. 16. The formliners of claim 13, wherein the opening comprises a recess formed in the rib of the second formliner, the recess comprising an interior surface, wherein the exterior surface of the rib of the first formliner is configured to nest within the recess by directly contacting the interior surface of the recess to form a tight fit between the first and second formliners when the first and second formliners are assembled at the predetermined angle. 17. The formliners of claim 13, wherein the recessed side of the second formliner and the flange are formed from a monolithic piece of material, wherein the monolithic piece of material comprises slits between the flange and the rib of the second formliner to allow adjustment of the predetermined angle between the flange and the recessed side of the cell of the second formliner. 18. The formliners of claim 13, wherein the opening of the rib of the second formliner comprises an edge extending about the rib of the second formliner, the edge extending from the recessed side of the cell of the second formliner, the edge defining the cross-sectional profile of the opening of the rib of the second formliner. 19. The formliners of claim 13, wherein the cell of the first formliner comprises a first surface and a second surface opposite the first surface, wherein at least a portion of the first surface is configured to contact the curable material, and wherein the flange extends along at least a part of the second surface and is in contact with the second surface when the first and second formliners are assembled. 20. The formliners of claim 13, wherein the flange of the second formliner is connected to the first formliner with an adhesive when the first and second formliners are assembled. 21. The formliners of claim 13, wherein the first formliner further comprises a detent between the cell and the rib of the first formliner, the detent extending away from the cell of the first formliner, wherein the second formliner further comprises a protrusion connected to the rib at the opening of the rib of the second formliner, the protrusion extending into the opening of the rib of the second formliner, and wherein the protrusion of the second formliner engages the detent of the first formliner to securely assemble the first and second formliners together. 22. Formliners comprising at least two formliners configured to form a corner in curable material when the at least two formliners are interconnected, the formliners comprising: a first formliner comprising: a recess;a rib extending along at least a part of the recess of the first formliner, the rib of the first formliner comprising an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material; anda detent between the recess and the rib of the first formliner, the detent extending away from the recess of the first formliner; anda second formliner comprising: a recess;a rib extending along at least a part of the recess of the second formliner, the rib of the second formliner comprising an opening having a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner when the second formliner is positioned at a predetermined angle relative to the first formliner; anda protrusion connected to the rib at the opening of the rib of the second formliner, the protrusion extending into the opening of the rib of the second formliner,wherein the first formliner is configured to be interconnected with the second formliner at the predetermined angle to form the corner in the curable material by positioning the opening of the rib of the second formliner over the exterior surface of the rib of the first formliner to minimize visible seams in the curable material, andwherein the protrusion of the second formliner engages the detent of the first formliner to securely assemble the first and second formliners together. 23. A method for assembling a first formliner and a second formliner to use for forming a corner in curable material, the method comprising: interconnecting the first formliner with the second formliner to minimize visible seams in the curable material by overlaying an opening of a rib of the second formliner onto at least a portion of a rib of the first formliner at a predetermined angle corresponding to a desired angle of the corner when forming the corner in the curable material,wherein the rib of the first formliner extends along at least a part of a cell of the first formliner and comprises an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material, andwherein the rib of the second formliner extends along at least a part of a cell of the second formliner, wherein the opening of the rib of the second formliner has a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner when the second formliner is positioned at the predetermined angle relative to the first formliner, andwherein a flange connected to the cell of the second formliner extends along at least a part of the cell of the first formliner to facilitate alignment of the first and second formliners when interconnecting the first formliner with the second formliner.
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