BACKGROUND

Field of the Inventions

[0001] The present inventions relate generally to concrete foπnliners and methods of using the same More specifically, the present inventions relate to an improved formhner W ₁ A snap fitting components that eliminates the need for using adhesives for interconnecting a plurality of formhners in a pattern Further, the formhner is configured to reduce and/or eliminate visible seams m order to create a more natural appearance in a finished product

Descnption of the Related Art

[0002] Decorative masonry and concrete construction have become increasingly popular m recent years The facades of homes and other buildings that had previously been constructed in very simple and plain concrete are now being ieplaced with either decorative stone and bπck or decorative concrete construction.

[0003] As a result of the increased demand for stone and bπck work, various improvements have been made in stone and bπck masonry and concrete construction. These improvements have lowered the cost for such construction by decreasing the time or skill requirements previously needed to perform such work.

[0004] For example, in stone and brick masonry, facings and floors have traditionally constructed by skilled artisans from individual units However, recent advances have been made m the masonry art which allow artisans to more quickly and accurately perform stone or bπck w oik In particular vaπous panels forms and mounting systems have been developed that allow individual units to be placed in precise geometric patterns, thus eliminating much of the painstaking effort usually expended by the artisan This now allows generally unskilled artisans such as the do-it-yourselfer, to create a high-quality product

|0005] Perhaps more importantly for projects with a tighter budget, advances in concrete construction now allow artisans to create a faux stone or bπck appearance in concrete with a formliner. As a result, one may achieve the appearance of stone or brick without the associated cost.

|0006] A concrete formliner generally comprises an interior surface onto which concrete is poured. The interior surface of the formliner typically includes a desired pattern or shape that will be transferred to the concrete to form a cured concrete casting. In many cases, the formliner is lined up with additional formliners to create a pattern over a wide area. The concrete casting can be created in a horizontal {such as for tilt up construction) or vertical casting process, and can be pre-cast, or cast-at-site construction.

[0007] After the concrete has cured, the formliners are removed from the exposed surface of the concrete, thus revealing the desired pattern or shape. Such patterns or shapes can include faux stone or brick, wave patterns, emblems, etc.

SUMMARY

|0008] As noted above, in recent years, significant advances have been made in the art of concrete laying. Various techniques and equipment have been developed that allow for the creation of decorative patterns in the concrete, especially a faux stone or brick appearance. The results of such techniques and equipment provide the appearance of stone or brick without the cost.

[0009] However, according to at least one of the embodiments disclosed herein is the realization that in using multiple formliners, seams are created between the formliners where the formliners meet. For example, in order to create a large pattern or casting with prior art formliners, the formliners are merely placed together using buti joints, thus creating significant visible seams between the formliners. As a result, the appearance of the exposed surface of the concrete is compromised. An unsightly seam is very easy to notice and takes a substantial amount of time and effort to remove from cured concrete. Further, in large-scale projects, it is simply too cost prohibitive to re-work the cured concrete in order to remove the seams. As such, the seams are simply left in place resulting in an inferior concrete product.

|0010] Thus, the present inventions provide for a formliner having one or more cells and one or more raised sections or ribs, wherein the formliner is shaped and configured to be interconnected with other such formliners to create a pattern or array of lbrmliners which nest with each other such that an applied material provides a natural appearance and does not show seaming between the formliners that were interconnected to create the pattern. As discussed herein, there are various features that can be incorporated into this broad conception of the formliner in order to provide various combinations and embodiments of the formliner. In the present description, the disclosed features can be optionally incorporated into the above-noted formliner in any combination.

[0011 j Accordingly, in at least one embodiment disclosed herein, an improved formliner is provided which minimizes and/or eliminates the seams between multiple interconnected formliners. One of the advantages of embodiments disclosed herein is that a seam between adjacent formliners is created along corners at or along a bottom portion of a prepared formliner assembly or mold cavity of a casting. For example, in some embodiments, a seam between adjacent and/or interconnected formliners can be formed by an edge of a first formliner positioned against or in a corner or face of an adjacent second formliner. In some embodiments, the seam can lie along the intersection of one or more surfaces, such as at a corner of a mold or formwork. Additionally, in other embodiments, the seam can be positioned such that the weight of a curable material, such as concrete, against the formliners causes the formliners to be pressed against each other with greater force thereby minimizing and/or eliminating the seam between the adjacent formliners.

[0012] In accordance with yet another embodiment is the realization that the set up and interconnection of formliners can be expedited by eliminating the need to apply adhesives to the overlapping joints of interconnected formliners. In other words, the realization is that the assembly time for a forming a large pattern of interconnected formliners can be substantially reduced, as well as the cost and parts required, by eliminating the need for adhesives. In order to provide such a superior benefit, embodiments of the formliners disclosed herein can comprise a snap-fit arrangement that allows overlapping formliners to form an interlocking joint. Thus, the formliners can be securely connected without using adhesives. Further, such embodiments also result in reduced seaming between the formliners where the formliners meet. Furthermore, another of the unique advantages of such an interlocking joint is that the joint is further stabilized and strengthened through the application of force to the overlapping formliners. such as the application of a curable materia] such as concrete. Therefore, such an interlocking joint not only allows for the elimination of adhesives, but also provides several structural benefits that ultimately create an aesthetically superior product.

[0013] As discussed herein, embodiments of the formliner can also be referred to as a sheet or panel. Some embodiments of the formliner can define interconnecting portions such that multiple forniHners can be overlaid with each other at the interconnecting portions thereof. Optionally, the interconnecting portions of the formliner can define variable geometries.

[0014] For example, a given interconnecting portion of the formliner can nest within another given interconnecting portion of the formliner. In such embodiments, as well as in other embodiments disclosed herein, the formliner can be configured such that upper surfaces of the interconnected formliners are flush with each other and joints between the interconnected formliners are minimized. Thus, embodiments disclosed herein can achieve a natural appearance of faux stone and brick with minimized, negligible, or imperceptible seaming.

[0015] In accordance with some embodiments, the formliner can comprise interlocking portions configured to overlap when the formliner is interconnected with another formliner such that seams between the interconnected formliners run along an edge or corner of the interconnected formliners. In this manner, the seams between interconnected formliners can be masked among discontinuities in a surface. Thus, the seams can be further concealed from view.

[0016] In accordance with an embodiment, a formliner is provide for use in creating a decorative pattern on an exposed face of cementitious material. The formliner can comprise a sheet of material, at least one cell formed in the sheet of material, and at least one rib extending along the cell to form a boundary of the cell. The rib can be formed in the sheet of material and defining a raised profile.

[0017] The rib can comprise a first section, a second section, at least one opening, and a transition zone. The first section can define an exterior surface and an interior surface. The exterior surface of the first section of the rib can be configured to face outwardly toward the cementitious material, and to define a cross-sectional exterior profile. The first section can further define a recess adjacent to the interior surface thereof. The recess can define a cross-sectional interior profile. Further, the at least one opening can be formed in the first section.

[0018] The second section can define an exterior surface that defines a cross- sectional exterior profile. The cross-sectional exterior profile of the second section can be less than the cross-sectional interior profile of the first section.

[0019] The transition zone can be formed in the rib between the first section in the second section to interconnect the first section with the second section. The transition zone can define a variable cross-sectional exterior profile increasing from the cross-sectional exterior profile of the second section to the cross-sectional exterior profile of the first section.

10020] In some embodiments, a plurality of formliners can be interconnected by overlaying first sections onto second sections such that the second sections are nested within the recesses of the first sections. Further, exterior surfaces of the first sections of the ribs of the plurality of formhners can be positioned flush with each other upon the nesting of the second sections within the first sections. Furthermore, an opening in the first section of a first formliner can mate against a transition zone of a second formhner such that visible seams in the decorative pattern are minimized when the plurality of formliners are interconnected in use.

[0021] In accordance with some aspects of embodiments of the formliner, the first section can define an inner corner wherealong the first section interconnects with the cell and a free outer edge. The outer edge can comprise at least one protrusion that extends inwardly toward the inner corner thereof. The first section can further define an exterior profile and a recess that defines a cross-sectional interior profile. The second section can also define an inner corner wherealong the second section interconnects with the cell and a free outer edge. The inner corner can comprise at least one detent extending inwardly toward the outer edge thereof. In this regard, the plurality of formliners can be interconnected by overlaying first sections onto second sections such that the protrusion of the first section engages the detent of the second section such that visible seams in the decorative pattern are minimized when the plurality of formliners are interconnected in use. Further, the protrusion of the outer edge of the first section of the rib can define a length that is less than a total length of the outer edge thereof. Furthermore, the detent of the inner corner of the second section of the rib can define a length that is less than a total length of the inner comer thereof. Additionally, the inner corner of the first section can comprise at least one protrusion that extends inwardly toward the outer edge thereof, and the outer edge of the second section can comprise a detent that extends inwardly toward the inner corner thereof.

[0022] hi accordance with some implementations, the ribs of the formliner can be arcuately shaped. Additionally, the opening formed in the first section of the rib can extend from a base of the rib to an apex of the rib. In this regard, the rib can be arcuately shaped and the opening is curvilinear. Further, a rib edge formed along the opening in the first section of a first formliner can abut the transition zone of a second foπnliner. In some implementations, the rib and the cell can meet to form a corner, and the first section of the rib of the first formliner can define a peripheral edge. The peripheral edge of the first section of the rib can be disposed along a corner formed by the intersection of the rib and the cell of the second formliner along the second section of the rib of the second formliner. In this regard, the peripheral edge of the first section of the rib can be generally straight.

|0023] In yet other aspects of embodiments of the formliner, the formliner can comprise a plurality of cells with a plurality of ribs disposed intermediate the cells to foπn boundaries thereof. The cells can define a generally rectangular shape. Further, the cells can define opposing narrow ends, and the cells can be arranged in a plurality of layers with each layer having a plurality of cells disposed end-to-end. In addition, embodiments of the formliner can be arranged such that cells of a first layer can be offset from the cells of a second layer. Moreoever, the formliner can comprise a plurality of cells. The foπnliner can define a first end and a second end. The first end can be formed to include a first finger joint pattern, and the second end can be formed to include a second finger joint pattern that is complementary to the first finger joint pattern such that a first end of the first formliner can be overlaid with a second end of the second foπnliner.

[0024] In yet other aspects of embodiments of the formliner, embodiments of the formliner can comprise a fold line extending along the sheet of material and crossing the at least one cell and at least one rib fonned in the sheet of material. The fold line can be configured to allow the formliner to be folded for fitting against a corner of a mold. In this regard, the rib can comprise a recess where the rib intersects with the fold line, and the recess can be configured to enable upper surfaces of first and second portions of the formliner to fold inwardly toward each other. Moreoever, in some implementations, the recess can comprise a pair of surfaces being oriented at an approximately 90° angle with respect to each other. The pair of surfaces can be configured to contact each other when the formliner is folded such that the first and second portions of the formliner are oriented at an approximately 90° angle. Further, the fold line can comprise an indentation in the sheet of material.

[0025J In accordance with another embodiment, a sheet is provided for forming a pattern on a surface of a cementitious material. The sheet can comprise rows of recesses. Each recess can be shaped to impart the pattern to the surface of the material. The recesses in a given row can be offset with respect to the recesses in an adjacent row. Each recess can be surrounded with ridges defining the recess. Further, the sheet can be combinabk with a similar sheet by means of overlapping at least some of the ridges. Furthermore, a plurality of sheets can be interconnected at their ends to foπn a junction along ridges of offset recesses such that the sheets are interconnected without a substantial seam at the junction.

[0026] In yet another embodiment, a system of panels is provided for forming a pattern in a curable material. Each panel can comprise a series of shaped regions for imparting, when curable material is in the regions, the pattern on a wall or the like. The panel can be formed with the shaped regions each being bounded by ridges. The ridges of the panel can be configured to enable the panel to be engageable with another panel to increase the area of application of the pattern. At least one of the ridges of the panel can have an open end to allow the ridges of the panel to overlay at least one of the ridges of the other panel.

|0027] In some implementations of the system, the ridges of the panel can include an overlapping ridge and an overlapped ridge. The overlapped ridge can comprise a detent that is configured to engage with a protrusion of an overlapping ridge of another panel when the overlapping ridge of the other panel is overlaid onto the overlapped ridge in order to interconnect the panels. Further, the panel can define a perimeter and the ridges extend about the perimeter thereof. Additionally, the panel can comprise overlapped πdgcs and overlapping ridges. The overlapping ridges of the panel can comprise one or more open ends such that ridges of the other panel can be overlapped by the overlapping ridges of the panel and extend from the open end in the overlapping ridges of the panel. The overlapping ridges can define an interior dimension that is greater than an exterior dimension of the overlapped ridges.

[0028] In some aspects of embodiments of the system, the system can be configured such that the shaped regions of the pane] can be formed in generally rectangular shapes, and the panel can define a perimeter comprising one or more ridges having an open end at a corner of the perimeter of the panel. The detent can be formed in a corner between the overlapped ridge and the shaped region of the panel. Further, the detent can extend in a direction away from the shaped region of the panel. Additionally, the protrusion of the pane! can be formed along a free side edge of the overlapping ridge of the panel. In this regard, the protrusion can extend in a direction toward the shaped region of the pane).

[0029] In other aspects of embodiments of the system, the system can be modified such that the overlapped ridge can comprise at least a pair of detents that are disposed on opposing sides of the overlapped ridge. The overlapping ridge can comprise at least a pair of protrusions disposed on opposing sides of the overlapping ridge. In this regard, a plurality of panels can be interconnected such that the protrusions of the overlapping ridge engage the detents of the overlapped ridge.

[0030] In accordance with yet another embodiment, a method is provided for transferring a decorative pattern to a curable material. The method can comprise: providing a plurality of formliners, each formliner comprising one or more shaped regions being bounded by ridges, each formliner defining overlapped ridges and overlapping ridges; engaging a first formliner with a second formliner by overlaying overlapping ridges of the first formliner on to overlapped ridges of the second formliner: and placing the curable material against the first and second formliners to transmit a decorative pattern formed by the shaped regions of the first and second formliners to the curable material.

[0031] In some implementations of the method, each formliner can be configured with the overlapped ridges having a detent and the overlapping ridges having a protrusion, and the method can further comprise causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges. Further, the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can be completed prior to placing the curable material against the first and second formliners. In some implementations of the method, no adhesive is used to engage the first formliner with the second foπnliner.

|0032] Additionally, the method can be implemented such that the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can comprise engaging a pair of protrusions of an overlapping ridge with a pair of detents of the overlapped ridge. In this regard, the pair of protrusions can be disposed on opposing sides of the overlapping ridge and the pair of detents are disposed on opposing sides of the overlapped ridge.

I0033J In other aspects of embodiments of the method, the method can be implemented such that each formliner further comprises non-overlap ridges and at least one open end formed in the overlapping ridges. In such implementations, the method can further comprise overlaying the overlapping ridges of the first formliner onto the overlapped ridges of the second formliner with a non-overlap ridge of the second formliner extending from an open end of the overlapping ridges of the first formliner. Further, the non-overlap ridge of the second formliner can be interconnected with and extend from the overlapped ridge of the second foπnliner.

[0034] In another aspect of embodiments of the method, the method can be implemented such that overlapping ridges of the first formliner can define an interior geometry that is greater than an exterior geometry of the overlapped ridges of the second formliner. In such an implementation, the method can further comprise engaging a third formhner with the first formliner and the second fonnliner. The third formliner can comprise overlapping ridges and overlapped ridges. Further, one of the first, second, and third formliners can comprise a sub-overlapped ridge section that defines an exterior geometry that can be less than an interior geometry of the overlapped ridges. In such an implementation, the method can further comprise overlaying an overlapped ridge on to the sub-overlapped ridge section. Further, the first formliner can comprise the sub-overlapped ridge section formed along a corner of a periphery of the first formliner. and the second foπnliner and the third formliner can overlap the first formliner at the sub-overlapped ridge section of the first form liner.

[0035] In yet other aspects of embodiments of the method, the first formliner and the second formliner each comprise at least one row with a projecting cell bounded in at least one adjacent row with a non-projecting cell, the first formliner and the second formliner being engaged with a projecting cell in a first row of the first formliner being positioned adjacent to a non-projecting cell in a first row of the second formliner and a projecting cell in a second row of the second formliner being positioned adjacent to a n on -projecting cell in a second row of the first formliner.

[0036] Other implementations of the method can be provided wherein edges the overlapping ridges of the first formliner extend downwardly toward a bottom portion of respective shaped regions located adjacent to overlapped ridges of the second formliner. Accordingly, the method can comprise placing the curable material against the overlapping ridges of the first formliner such that the edges of the overlapping ridges of the first formliner are urged adjacent to the bottom portion of respective shaped regions to minimize and/or eliminate a seam formed between the edges and the bottom portion of the respective shaped regions.

[0037 j In accordance with yet another embodiment, a method of manufacturing a formliner is provided. The method can comprise: forming a formliner of one of the embodiments disclosed herein. Further, the method can be implemented such that an opening in the first section of a rib of the formliner is formed by trimming a rib protrusion that extends from the rib.

[0038] Further, the method of forming a formliner can be implemented using a variety of tools and machines. For example, the formliner can be formed using a thermoforming operation. Additionally, a periphery of the formliner can be trimmed using a laser cutting operation.

[0039] Additionally, in accordance with at least one embodiment disclosed herein, the formliner can comprise a plurality of cells. Optionally, the cells can be rectangularly shaped, thus taking on the appearance of bricks. The cells can be arranged in an offset pattern. In this regard, the formliner can be interconnected with another formliner to produce a finger jointed pattern in the concrete. Additionally, the cells can be shaped in the form of various types of stone. The stone shapes may be rounded, thin, square, and in other myriad shapes. Embodiments of the formliner can be formed to include cells that are identical or that very in size. Optionally, embodiments of the formliner can comprise one or more cells that define a substantially planar face. Alternatively, the formliner can comprise one or more cells that define a roughened or textured face.

|0040] In an embodiment, a formliner is provided for use in creating a decorative pattern on a treated or exposed face of a curable material. Embodiments can be used in horizontal or vertical casting. Some embodiments can be used with materials such as cement, plaster, or other such curable materials. In other embodiments, the formliner can comprise a sheet of material, at least one cell, and at least one rib. This material can optionally be formed from a plastic material. The cell can be formed in the sheet of material. The rib can extend along the cell and form a boundary of the cell. The rib can be formed in the sheet of material and define a raised profile.

|0041] In some embodiments, the rib can comprise a first section, a second section, at least one opening, and a transition zone. The first section can define an exterior surface and an interior surface. The exterior surface of the first section of the rib can be configured to face outwardly toward the cementitious material. The first section can define a recess adjacent to the interior surface thereof. The recess can define a cross-sectional interior profile.

[0042] The second section can define an exterior surface forming a cross- sectional exterior profile. The cross-sectional exterior profile of the second section can be less than the cross-sectional interior profile of the first section. The opening can be formed in the first section.

[0043] The transition zone can be formed in the rib between the first section in the second section to interconnect the first section with the second section. The transition zone can define a variable cross-sectional profile increasing from the cross-sectional exterior profile of the second section to the cross-sectional interior profile of the first section.

[0044] It is contemplated that a first formliner can be interconnected with a second formliner by nesting the overlaying the first section of the rib of the first formliner

-U- onto the second section of the rib of the second formliner such that the second section of the rib of the second formliner is nested within the first section of the rib of the first formliner. Further, exterior surfaces of the ribs of the first formliner and the second formliner can be flush with each other upon nesting of the second section of the second formliner within the first section of the first formliner. Additionally, an opening in the first section of the first formliner can mate against a transition zone of the second formliner such that visible seams in the decorative pattern are minimized when the first formliner and the second formliner are interconnected in use.

[0045] In some embodiments, the ribs of the first formliner and the second formliner can be arcuately shaped. The opening formed in the first section of the rib can extend from a base of the rib to an apex of the rib. The rib can be arcuately shaped and the opening can be curvilinear. Further, a rib edge formed along the opening in the first section of the first formliner can abut the transition zone of the second formliner. The rib and the cell can meet to form a corner.

[0046] Further, the first section of the rib of the first formliner can define a peripheral edge. The peripheral edge of the first section of the rib can be disposed along a corner formed by the intersection of the rib and the cell of the second formliner along the second section of the rib of the second formliner. The peripheral edge of the first section of the rib can be generally straight. The formliner can comprise a plurality of cells with a plurality of ribs disposed intermediate the cells to form boundaries thereof. The cells can define a generally rectangular shape. The cells can define opposing narrow ends. Further, the cells can be arranged in a plurality of layers with each layer having a plurality of cells disposed end-to-end.

[0047] In other embodiments, the cells of a first layer can also be offset from the cells of a second layer. Further, the formliner can comprise a plurality of cells and define a first end and a second end. In this regard, the first end can be fonned to include a first finger joint pattern and the second end can be formed to include a second finger joint pattern that is complementary to the first finger joint pattern such that a first end of the first formliner can be overlaid with a second end of the second formliner. [0048] In accordance with yet another embodiment, a pane] is provided for forming a repeated pattern on a rigid surface. The panel can comprise a plurality of cells and a panel periphery. The plurality of cells can be configured to receive material to be applied to the surface and can be arranged in rows with the cells of each row being offset with respect to cells of an adjacent row. The panel periphery can bound the plurality of cells by a plurality of sides. Each cell can comprise a recess portion for receiving the material and being shaped to confer a pattern on the material. In this regard, at least one given side of the panel periphery can be formed with cells in offset configuration such that the given side has at least one row with a projecting cell bounded in at least one adjacent row with a non-projecting cell. In some embodiments, the cells can be uniformly sized. For example, the cells can be rectangular.

|0049] Additionally, in accordance with another aspect of the present inventions, a set of panels can be provided which comprises a first panel as claimed in Claim 14 and a second pane]. The second panel can have a panel periphery with at least one side being formed with cells in offset configuration such that the side has at least one row with a projecting cell bounded in at least one adjacent row with a non-projecting cell. The first and second panels can be configured to interconnect along the sides thereof having the projecting cells. The projecting cell of the first panel can be positioned in the same row as the non- projecting cell of the second panel and can be offset from the projecting cell of the second panel. The projecting cell of the second panel can be positioned in the same row as the non- projecting cell of the first panel. The first and second panels can form a continuous sheet with offset cells along their juncture. As mentioned above, in some embodiments, the cells can be uniformly sized. For example, the cells can be rectangular.

J0050] In accordance with yet another embodiment, a sheet is provided for forming a pattern on a surface of a cementitious material. The sheet can comprise rows of recesses. Each recess can be shaped to impart the pattern to the surface of the material. The recesses in a given row can be offset with respect to the recesses in an adjacent row. Each recess can be surrounded with ridges defining the recess. The sheet can be combinable with a similar sheet by means of overlapping at least some of the ridges. In this regard, a plurality of sheets can be interconnected at their ends to form a junction along ridges of offset recesses such that the sheets are interconnected without a substantial seam at the junction.

[0051J In yet another embodiment, a panel is provided for imparting a decorative appearance to a surface, such as a casting (whether horizontal or vertical), a wall, walking area or the like through application of a curable material to the surface that shaped to the decorative appearance by a series of recesses. The recesses can be configured to receive the curable material and provide the decorative appearance as the curable material cures. The recesses can have projections defining a first dimension. The panel can have first and second edge areas configured to allow a plurality of panels to be interconnected along the first and second edges areas in an end-to-end manner. The first edge area of the panel can define first projections having an underside. The second edge area of the panel can have, at least in part. second projections of a reduced dimension for mating with the underside of the first projections of another pane] by overlaying the first projections of the panel on the second projections of reduced dimension.

[0052] In accordance with another embodiment, a panel is provided for forming a pattern in a curable material. The panel can comprise a series of shaped regions for imparting, when curable material is in the regions, the pattern on a wall or the like. The panel can be formed with the shaped regions each being bounded by ridges. The ridges of the panel can be configured to enable the panel to be engageablc with another panel to increase the area of application of the pattern. Further, at least one of the ridges of the pane] can have an open end to allow the ridges of the panel to overlay at least one of the ridges of the other panel.

[0053] Additionally, the panel can be optionally configured to define a perimeter and the ridges can extend about the perimeter thereof. The panel can comprise OΛ eiiapped ridges and overlapping ridges. This regard, the overlapping ridges of the panel can comprise one or more open ends such that ridges of the other panel can be overlapped by the overlapping ridges of the panel and extend from the open end in the overlapping ridges of the panel. In some implementations, the overlapping ridges can define an interior dimension that is greater than an exterior dimension of the overlapped ridges. In other embodiments, the shaped regions of the panel can be formed in generally rectangular shapes and the panel can define a perimeter comprising one or more ridges having an open end at a comer of the perimeter of the panel.

|0054] In accordance with yet another embodiment, a method is provided for transferring a decorative pattern to an exposed surface of a curable material. The method comprise the steps of: providing a plurality of foπnliners. each formliner comprising one or more shaped regions being bounded by ridges, each foπnliner defining overlapped ridges and overlapping ridges; engaging a first foπnliner with a second formliner by overlaying overlapping ridges of the first foπnliner on to overlapped ridges of the second formliner; and placing the curable material against the first and second formliners to transmit a decorative pattern formed by the shaped regions of the first and second foπnliners onto the exposed face of the curable material.

[0055] In some embodiments, each formliner can further comprise non-overlap ridges and at least one open end formed in the overlapping ridges. In this regard, the method can further comprise overlaying the overlapping ridges of the first formliner onto the overlapped ridges of the second formliner with a non-overlap ridge of the second formliner extending from an open end of the overlapping ridges of the first formliner. Further, the non- overlap ridge of the second formliner can be interconnected with and extends from the overlapped ridge of the second formliner.

[0056] Additionally, the overlapping ridges of the first formliner can define an interior geometry that is greater than an exterior geometry of the overlapped ridges of the second formliner. In such embodiment, the method can further comprise engaging a third fonriliner with the first formliner and the second formliner. The third formliner can comprise overlapping ridges and overlapped ridges, and one of the first, second, and third formliners can comprise a sub-overlapped ridge section. The sub-overlapped ridge section can define an exterior geometry that is less than an interior geometry of the overlapped ridges, the method further comprising overlaying an overlapped ridge on to the sub-overlapped ridge section.

|0057] Further, in some embodiments, the first formliner can be configured with the sub-overlapped ridge section formed along a comer of a periphery of the first formliner. Further, the second formliner and the third fonnlmer can overlapped the first formliner at the sub-overlapped ridge section of the first formliner. |0058) In other implementations of the method, the first formliner and the second foπnliner can each comprise at least one row with a projecting cell bounded in at least one adjacent row with a non-projecting cell. The first formliner and the second formliner can be engaged with a projecting cell in a first row of the first formliner being positioned adjacent to a non-projecting cell in a first row of the second formliner and a projecting cell in a second row of the second formliner being positioned adjacent to a non-projecting cell in a second row of the first formliner.

|0059] Furthermore, some embodiments of the method can allow for minimized and/or eliminated seaming between the formliners. For example, the overlapping ridges of the first formliner can be configured to include edges that extend downwardly toward a bottom portion of respective shaped regions located adjacent to overlapped ridges of the second formliner. The method can comprise placing the curable material against the overlapping ridges of the first formliner such that the edges of the overlapping ridges of the first foπnliner are urged adjacent to the bottom portion of respective shaped regions to minimize and/or eliminate a seam formed between the edges and the bottom portion of the respective shaped regions.

|0060] In accordance with some embodiments, it is contemplated that the formliner can be attached to another formliner and/or to a form work by means of an adhesive. Such an adhesive can be applied to the formliner at the site. However, in some embodiments, the fonnliner can comprise an adhesive that can be activated or exposed in order to enable adhesive attachment of the formliner to another fonnliner or to a form work. For example, the adhesive can be pre-applied to the formliner, which adhesive can be exposed by removing a strip or by dampening with a liquid such as water or otherwise. In this manner, the formliner can be securely attached in a pattern and/or in a form work to facilitate handling and placement of the fonnliner.

[0061] In such an embodiment, a formliner is provided for creating a decorative pattern on a curable material. The formliner can comprise a sheet of material, at least one cell formed in the sheet of material, and at least one rib extending along the cell and forming a boundary of the cell. The rib can define a raised profile. Further, the rib can comprise a hollow first section and a second section. |00621 The hollow first section can define an inner corner wherealong the first section interconnects with the cell and a free outer edge. The outer edge can comprise at least one protrusion that extends inwardly toward the inner corner thereof. The first section can further define a cross-sectional exterior profile and a recess that defines a cross-sectional interior profile.

[0063] The second section can define a cross-sectional exterior profile. The cross-sectional exterior profile of the second section can be less than the cross-sectional interior profile of the recess of the first section. The second section can further define an inner corner wherealong the second section interconnects with the cell and a free outer edge. The inner comer can comprise at least one detent extending inwardly toward the outer edge thereof. In this regard, a plurality of formliners can be interconnected by overlaying first sections onto second sections such that the protrusion of the first section engages the detent of the second section such that visible seams in the decorative pattern are minimized when the first formliner and the second fonnliner are interconnected in use.

|0064J In some embodiments, the protrusion of the outer edge of the first section of the πb can define a length that is less than a total length of the outer edge thereof. Further, the detent of the inner comer of the second section of the rib can define a length that is less than a total length of the inner corner thereof. In other embodiments, the inner corner of the first section can comprise at least one protrusion that extends inwardly toward the outer edge thereof, and the outer edge of the second section can comprise a detent that extends inwardly toward the inner corner thereof. Further, the at least one rib of the formliner can be arcuately shaped.

10065] Additionally, the fonnliner can further comprise at least one opening formed in the first section and a transition zone formed in the rib between the first section in the second section to interconnect the first section with the second section. The transition zone can define a variable cross-sectional exterior profile increasing from the cross-sectional exterior profile of the second section to the cross-sectional exterior profile of the first section.

|0066] In accordance with another embodiment, a panel is provided for forming a pattern in a curable material. The panel can comprise a series of shaped regions for imparting, when curable material is in the regions, the pattern on a wall or the like. The panel can be formed with the shaped regions each being bounded by ridges. The ridges of the panel can be configured to enable the panel to be engageable with another panel to increase the area of application of the pattern. In this regard, at least one of the ridges of the panel can have an open end to allow the πdges of the panel to overlay at least one of the ridges of the other panel. Further, the ridges of the panel can include an overlapping ridge and an overlapped ridge. The overlapped ridge can comprise a detent that is configured to engage with a protrusion of an overlapping ridge of another panel when the overlapping ridge of the other panel is overlaid onto the overlapped ridge in order to interconnect the panels.

[0067] In some implementations, the detent of the panel can be formed in a corner between the overlapped ridge and the shaped region of the panel. Further, the detent can extend in a direction away from the shaped region of the panel. Additionally, the protrusion of the panel can be formed along a free side edge of the overlapping ridge of the panel. In this regard, the protrusion can extend in a direction toward the shaped region of the panel.

[0068] In other implementations, the overlapped ridge can comprise at least a pair of detents that are disposed on opposing sides of the overlapped ridge, and the overlapping ridge can comprise at least a pair of protrusions disposed on opposing sides of the overlapping ridge. In this regard, a plurality of panels can be interconnected such that the protrusions of the overlapping ridge engage the detents of the overlapped ridge.

[0069] According to yet another embodiment, a system of interconnectable panels is provided for forming a pattern in a curable material. Each panel can comprise one or more shaped regions for imparting, when curable material is in the regions, the pattern on a wall or the like. The shaped regions can each be bounded by ridges. At least one of the ridges of each panel can have an open end to allow the ridges of the panel to overlay at least one of the ridges of the other panel. The ridges can comprise a detent and a protrusion that are configured to enable a given panel to be engageable with another panel when the ridges of the panels are overlaid to increase the area of application of the pattern.

[0070] The system can be configured such that the ridges can comprise at least a pair of detents disposed on opposing sides of the ridge and at least a pair of protrusions disposed on opposing sides of the ridge. For example, a plurality of panels can be interconnected with the πdge of a given panel being overlaid onto the ridge of another panel such lhat protrusions of the ridge of the given panel engage the detents of the ridge of the other panel.

|0071] In some embodiments, the system can be configured such that each panel comprises an overlapping ridge and an overlapped ridge. The overlapped ridge can comprise the detent, and the overlapping ridge can comprise the protrusion. In this regard, the panels can be engaged by overlaying an overlapping ridge onto an overlapped ridge to engage a protrusion of the overlapping ridge with a detent of the overlapped ridge. Further, the protrusion of each panel can be formed along a free side edge of the overlapping ridge. For example, the protrusion can extend in a direction toward the shaped region. Furthermore, the detent of each panel can be formed in a corner portion of the panel between the overlapped ridge and the shaped region. For example, the detent can extend in a direction away from the shaped region.

|0072] In some implementations, each panel can define a perimeter and the ridges extend about the perimeter thereof. Further, each panel can comprise overlapped ridges and overlapping ridges. The overlapping ridges can comprise one or more open ends such that an overlapped ndge can be overlaid by an overlapping ridge and extend from the open end of the overlapping ridge. In this regard, the overlapping ridges can define an interior dimension that is greater than an exterior dimension of the overlapped ridges.

|0073] In accordance with yet another embodiment, a method is provided for transferring a decorative pattern to a curable material. The method can comprise: providing a plurality of formliners, each formliner comprising one or more shaped regions being bounded by ridges, each formliner defining overlapped ridges and overlapping ridges, the overlapped ridges having a detent, the overlapping ridges having a protrusion: engaging a first formliner with a second formliner by overlaying overlapping ridges of the first formliner on to overlapped ridges of the second formliner; causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges; and placing the curable material against the first and second formliners to transmit a decorative pattern formed by the shaped regions of the first and second formliners to the curable material.

[0074] One of the unique aspects of such a method is that it can be implemented such that no adhesive is used to engage the first formliner with the second formliner. In some implementations, the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can be completed prior to placing the curable materia] against the first and second foπnliners. Further, the step of causing engagement between a protrusion of one of the overlapping ridges with a detent of one of the overlapped ridges can comprise engaging a pair of protrusions of an overlapping ridge with a pair of detents of the overlapped ndge. In this regard, the pair of protrusions can be disposed on opposing sides of the overlapping ridge and the pair of detents can be disposed on opposing sides of the overlapped ridge.

|0075] Moreover, the method can also further compπsing the step of engaging a third fonnliner with the first formliner and the second formliner. The third formliner can comprise overlapping ridges and overlapped ridges, and one of the first, second, and third formliner comprising a sub-overlapped ridge section. The sub-overlapped ridge section can define an exterior geometry that can be less than an interior geometry of the overlapped ridges. In this regard, the method can further comprise overlaying an overlapped ridge onto the sub-overlapped ridge section. Additionally, the sub-overlapped ridge section can be formed along a corner of a periphery of the first formliner, and the method can comprise overlaying the second fonnliner and the third formliner onto the first formliner at the sub- overlapped ridge section of the first formliner.

BRIEF DESCRIPTION OF THE DRAWINGS

[0076] The abovementioned and other features of the inventions disclosed herein are described below with reference to the drawings of the preferred embodiments. The illustrated embodiments are intended to illustrate, but not to limit the inventions. The drawings contain the following figures:

[0077] Figure 1 is a perspective view of a formϊiner, according to an embodiment of the present inventions.

[0078] Figure 2 is a top view of a plurality of formliners that are interconnected to create a formliner assembly, according to an embodiment.

[0079] Figure 3 is a cross-sectional side view taken along section 3-3 of Figure 2.

[0080] Figure 4 is a top view of a formliner, according to an embodiment. |0081] Figure 5 is an end view taken along section 5-5 of Figure 4.

|0082] Figure 6 is a perspective view of first and second formliners as the first formliner is overlaid onto the second formliner, according to an embodiment.

10083} Figure 7 is an enlarged perspective view of a rib corner of the formliner shown in Figure 4.

[0084] Figure 8 is a perspective view of a first formliner, a second formliner, and a third formliner illustrating nesting of the formliners along a rib corner of the first formliner, according to an embodiment.

|0085] Figure 9 is a perspective view of first and second formliners in an interconnected configuration, according to an embodiment.

[0086] Figure 10 is a cross-sectional side view of the first and second formliners shown in Figure 9 illustrating flush exterior surfaces of the first and second formliners.

|0087] Figure 1 1 is a top view of a formliner for forming a mold corner, according to another embodiment.

[0088] Figure 12 is a perspective view of first and second formliners configured to form a mold comer, according to an embodiment.

[0089] Figure 13 is a perspective view of first and second formliners configured to form a mold comer, according to another embodiment.

[0090] Figure 14 is a perspective view of first and second formliners configured to form a mold corner, according to yet another embodiment.

[0091] Figure 15 is a top view of an alternative configuration of a formliner, according to an embodiment.

[0092] Figure 16 is a top view of another alternative configuration of a formliner, according to another embodiment.

[0093] Figure 17 is a perspective view of yet another alternative configuration of a formliner, according to another embodiment.

[0094] Figures 38A-C illustrate a prior art brickwork form system.

[0095] Figure 19 is a perspective view of a formliner, according to an embodiment of the present inventions. |0096] Figure 20 is a top view of a plurality of formliners that are interconnected to create a formliner assembly, according to an embodiment.

[0097] Figure 21 A is a cross-sectional side view taken along section 21A-21A of Figure 20.

[0098] Figure 21B is an enlarged view of a portion of the cross-sectional side view of Figure 2 IA.

|0099] Figure 23 C is another enlarged view of a portion of the cross-sectional side view of Figure 21 A wherein the foπnliners are shown prior to interconnection thereof, according to an embodiment.

[0100] Figure 22A is an enlarged cross-sectiona] side view of a formliner, similar to that shown in Figures 21 A-C. according to another embodiment.

[0101] Figure 22B is an enlarged cross-sectional side view of a formliner, similar to that shown in Figures 21 A-C. according to yet another embodiment.

[0102] Figure 22C is an enlarged cross-sectional side view of a formliner, similar to that shown in Figures 21 A-C. according to yet another embodiment.

|0103] Figure 23 is a top view of a formliner, according to an embodiment.

[0104] Figure 24 is an end view taken along section 24-24 of Figure 23.

[0105] Figure 25 is a perspective view of first and second formlϊners as the first formliner is overlaid onto the second formliner, according to an embodiment.

[0106] Figure 26 is an enlarged perspective view of a rib corner of the formliner shown in Figure 19.

[0107] Figure 27 is a perspective view of a first formliner, a second formliner, and a third formliner illustrating nesting of the foπnliners along a rib corner of the first formliner, according to an embodiment.

[0108] Figure 28 is a perspective view of first and second formliners in an interconnected configuration, according to an embodiment.

[0109] Figure 29 is a cross-sectional side view of the first and second formliners shown in Figure 28 illustrating flush exterior surfaces of the first and second formliners.

[0110] Figure 30 is a top view of a formliner for forming a mold corner, according to another embodiment. [0111] Figure 31 is a perspective view of first and second formliners configured to form a mold comer, according to an embodiment.

[0112] Figure 32 is a perspective view of first and second formliners configured to form a mold corner, according to another embodiment.

[0113] Figure 33 is a top view of an alternative configuration of a formliner, according to an embodiment.

[0114] Figure 34 is a top view of another alternative configuration of a formliner, according to another embodiment.

[0115] Figure 35 is a perspective view of yet another alternative configuration of a formliner, according to another embodiment.

[0116] Figure 36 is a top view of yet another embodiment of an alternative configuration of a formliner, according to another embodiment.

[0117] Figure 37 is a top view of a mold corner, according to another embodiment.

[0118] Figure 38A is an enlarged view of a portion of the mold comer shown in Figure 37.

|0119] Figure 38B is a side view of a portion of the mold comer shown in Figure 37.

DETAILED DESCRIPTION

[0120] While the present description sets forth specific details of various embodiments, it will be appreciated that the description is illustrative only and should not be construed in any way as limiting. Furthermore, various applications of such embodiments and modifications thereto, which may occur to those who are skilled in the art, are also encompassed by the general concepts described herein.

[0121] As generally discussed above, embodiments of the present inventions are advantageously configured in order to enhance the aesthetic finish of a concrete structure. In particular, embodiments disclosed herein can be used to create a natural, seamless appearance of brick, stone, and other types of materials in a concrete structure. [0122] In contrast to prior art fonnliners that produce an inferior quality product, the structures of embodiments of the formliner disclosed herein, which can also be referred to as a panel or sheet, allow the formliner to create decorative patterns that are visually superior to results provided through the prior art. These significant advantages are due at least in part to the nesting arrangement of the variable size channels of embodiments of the formliner disclosed herein. In particular, the formliner can comprise one or more large interconnection sections and one or more small interconnection sections such that a plurality of formliners can be interconnected at their respective large and small interconnection sections. When interconnected, the plurality of formliners can define one or more generally continuous dimensions or shapes of raise portions thereof. For example, the large and small interconnection sections can configured as nesting semi-cylinders that foπn a rib structure. Additional advantages and features of embodiments of the formliner are discussed further below.

[0123] In some embodiments, it is contemplated that the formliner can be attached to another formliner and/or a form work by means of an adhesive. The adhesive can be disposed on a rear surface or back of the formliner and/or onto a front surface of the formliner. For example, the adhesive can be disposed on the front surface along a rib or ridge that will be overlaid by a portion of another formliner.

|0124] Ln some embodiments, the adhesive can be applied to the formliner at the site. For example, the adhesive can be applied or sprayed onto the formliner. However, in other embodiments, the formliner can comprise an adhesive that can be activated or exposed in order to enable adhesive attachment of the foπnlincr to another formliner or to a form work. In such embodiments, the adhesive can be pre-applied to the fonnliner and can be exposed by removing a cover strip or activated by dampening with a liquid such as water or otherwise. As such, by peeling away a cover strip or by providing moisture to the adhesive, the adhesive can be activated to adhesively attach the formliner to another formliner or to a foπn work. As noted above Ln this manner, the formliner can be securely attached another formliner in a pattern and/or to a foπn work to facilitate handling and placement of the fonnliner. |0125] Embodiments of the formliner and formliner components disclosed herein can be manufactured using any of a variety of processes. For example, it is contemplated that some embodiments can be formed using a sheet and a vacuum forming operation. Other manufacturing processes such as injection molding, stamping, extrusion, etc. can also be used.

[0126] With reference now to the figures. Figure 1 is a perspective view of an embodiment of a formliner. panel, or sheet 100. The formliner 100 can comprise a plurality of ribs, ridges, or channels 102. The ribs 102 can be a raised portion of the formliner 100. The ribs 102 can define an outer perimeter of the formliner 100. Additionally, the ribs 102 can extend inwardly to form one or more cells or recesses 104.

[0127] In some embodiments, the cells 104 can comprise a recessed portion of the formliner 100. The recessed portion of the cell 104 can be configured to receive a curable material to which a pattern of the formliner can be conferred or transferred. The cells 104 can be uniformly sized. For example, the cells 104 can be rectangularly shaped. As discussed below, embodiments of the formliner 100 can implement other shapes, depths, and sizes of the cells 104.

[0128] As illustrated in the embodiment of Figure 1, the cells or recesses 104 can be arranged in rows. As will be discussed further below, the cells or recesses 104 of a given row can be offset with respect to cells or recesses of an adjacent or neighboring row. In this regard, a plurality of formhners 300 can be interconnected along ends thereof in such a way as to reduce any visible appearance of a seam between interconnected formliners. The offset configuration of the cells or recesses 104 in some embodiments can aid in concealing or hiding any seaming between formliners.

[0129] Additionally, the embodiment illustrated in Figure 1 illustrates that the ceils 104 of adjacent rows can be offset from each other such that at opposing ends of the formliner 100, some of the cells 104 protrude at the end. Ln this regard, the rows can be formed to include projecting and non-projecting cells 104. The projecting cells can be considered to be complete or whole cells. In other words, the projecting cells are not smaller in size than other cells 104 of the pattern even though the offset configuration of the cells 104 causes the projecting cells to protrude at one side or end of the formliner 100. As will be discussed further below, the projecting cells of the pattern can be interconnected with projecting cells of another formliner.

|0130] The embodiment illustrated in Figure 1 can be used to create a faux brick pattern on a concrete structure. The formliner 100 can define a panel periphery bounding the plurality of cells 104 by a plurality of sides. The formliner 100 defines an upper surface 1 10. Although not shown in Figure 1 , the formliner 100 also defines a lower surface. In use, the upper surface 110 of the formliner 100 would be positioned such that it can be pressed into fresh concrete. This can be accomplished by placing the upper surface 1 10 of the formliner 100 against an exposed surface of fresh concrete. Otherwise, this can be accomplished by affixing the lower surface of the formliner 100 to an interior wall of a pattern, casting, or formwork before concrete is poured into the pattern, casting, or formwork. In either case, a material, such as concrete can be placed against the decorative pattern of the formliner 100 defined by the ribs 102 and the cells 104 in order to transfer the decorative pattern to the exposed surface of the material as the material cures.

[0131] Ln many cases, the exposed surface of a given structure, such as a wall, walking area, or the like, consists of a large surface area. In order to cover the entire area, several formliners must be used. As shown in the formliner assembly of Figure 2, several formliners 120, 122. and 124 can be interconnected in order to transfer a decorative pattern onto a large surface area. The interconnection of these formhners 120, 122, and 124 provides a distinct advantage over prior art to formliners because the seams between the formliners 120, 122, and 124 are insubstantial and/or eliminated compared to prior art formliners.

[0132] As discussed above. Figure 2 illustrates that the formliner 120 can comprise projecting cells 125 m the formliner 122 can comprise one or more projecting cells 126. These projecting cells 125. 126 can be positioned in different rooms of the formliners 120, 122. Thus, the projecting cells 125 can be positioned adjacent to non-projecting cells of the formliner 122 in the projecting cell 126 can be positioned adjacent to a non-projecting cell of the formliner 120. Thus, the cells of the formliner 120 can be offset with respect to each other and with respect to cells above the formliner 122. Moreover, the interconnection of the foπnliners 120, 122 can be accomplished using offset projecting cells 125, 126. 10133] In accordance with some embodiments, the formliner 100 illustrated in Figure I can be configured such that a plurality of form liners 100 can be interconnected at their top and bottom ends and sides. Figure 2 illustrates this principle. The formliners 120, 122. and 124 are each interconnected and overlap each other. This interconnection allows the formliners to be easily handled and assembled to a given size. Importantly however, the formliner is configured such that portions thereof can overlap and create a generally uniform and seamless rib structure on the upper surface 110 of the formliners 120, 122, and 124. hi other words, the shape and depth of the rib structure formed in the exposed surface of the concrete structure can be generally constant and the transition from a given formliner to another given formliner can be generally imperceptible.

10134] Moreover, in some embodiments, edges of each of the respective formhners 120. 122, and 124 can lie along a comer or edge feature of the decorative pattern. As such, when a curable material is placed in against the formliners and takes the shape, in this case of a rectangle having right-angle corners, an edge 127 of the formliner 122 forms a portion of the corner of the molded or formed rectangle and becomes nearly imperceptible. Accordingly, the overlapping edges 127 of the formliner 122 create minimal visible seaming, if at all, between the formliners 120 and 122. This principle is illustrated in greater detail in Figures 6-9.

[0135] Additionally, transition zones or joints 128 are formed where upper surfaces of ribs the formliners 120. 122. and 124 meet. In this regard, the transition zones or joints 128 can be toleranced in order to define an extremely narrow gap between interconnected formliners. Thus, any seaming at the transition zones or joints 128 can also be greatly reduced in order to reduce and/or eliminate visible seaming.

(0136] In this regard, the formliner 100 can be configured such that the plurality of ribs 102 includes one or more overlapping portions 130 and one or more overlapped portions 132. In some embodiments, the plurality of ribs 102 of the formliner 100 can be configured to comprise one or more non-overiap portions 134. The overlapping portions 130 can be configured to include an internal cavity with an internal geometry that accommodates the external geometiy of the overlapped portions 132. Thus, the overlapped portions 132 can be received within the internal cavities of the overlapping portions 130. The non-overlap portions 134 can extend between overlapping portions 130 and overlapped portions 132. However, the non-overlap portions 134 wiil not overlap or be overlapped by portions of another fomiliner win a plurality of formliners are interconnected. When a plurality of formliners is interconnected, the external surface of the overlapping portions 130 can be flush with the external surface of the non-overlap portions 134.

[0137] An illustration of this principle is shown in Figure 3 and 7B and described below. Figure 3 it is a cross-sectional side view taken along Section 3-3 of Figure 2. Figure 2 illustrates that a right side 140 of the formliner 120 overlaps with a left side 142 of the formhner 122.

|0138] In Figure 3, an overlapping portion 144 of the formliner 122 rests on top of an overlapped portion 146 of the formliner 120. The cross-sectional side view also illustrates a cell 150 of the formliner 120. Further, the formhners 120. 122 are configured such that the overlapping portion 144 of the formliner 122 defines an outer surface that matches an outer surface of the ribs 102 of the foπnliners 120, 122. and 124. In other words, the overlapping portions of a formliner can have an outer dimension that is equal to an outer dimension of the non-overlap portions of the ribs of the formliner. Thus, the overall rib structure of interconnected formliners will seem continuous in shape and dimension because the overlapping portions and the non-overlap portions (and not the overlapped portions) of the ribs of the formliners are the only portions of the ribs that are exposed.

[0139] In addition, as discussed below with regard to Figure 10. one of the significant advantages of embodiments disclosed herein is that they are able to reduce and/or eliminate seams between adjacent formliners using the significant compressive stresses created by the weight of a curable material, such as concrete, poured onto a formliner assembly or formliner mold cavity. In other words, the configuration of the overlapped and overlapping portions of adjacent foπnliners enabled the weight of the material to press down upon the overlapping portions of a formliner in order to optimize the fit between overlapping portions and overlapped portions of adjacent formliners to thereby reduce any visible seaming between the formliners.

[0140] Referring still to Figure 3, the rib structure of the formliners 120. 122 can be generally defined by a semicylindrical or arch shape. Accordingly, the overlapping portions 144 and the overlapped portions 146 can be defined by a radius. In particular, a lower surface 160 of the overlapping portion 144 of the formliner 122 can be defined by a first radms. Similarly, an upper surface 162 of the overlapped portion 146 of the formliner 120 can be defined by a second radius. The first radius can be greater than the second radius in order to allow the overlapped portion 146 to be nested within the overlapping portion 144. As such, the overlapped portions 146 can define a smaller cross-sectional profile than the interior cavity of the overlapping portions 144.

[0141} Furthermore, although the rib structure is illustrated as being formed by semicylindrical or arch shaped channels, the rib structure can be formed by a rectangular cross- sect ion. In this regard, any variety of shapes can be used. For example, while an embodiment of the formliners discussed herein is generally intended to create an appearance of faux brick, other embodiments of the formliners disclosed herein can be designed to create an appearance of faux stone, including any of various commercial stone such as cut stone, castle rock, sand stone, ledgestone, fieldstone, etc.. as well as. wood, river rock, slate, or other materials and variations, which is merely an exemplary and non-limiting list of potential appearances and applications. Thus, the rib structure can be varied and diverse. The dimensions of the rib structure can be variable and allow for irregular patterns as may be seen in natural settings of stone, brick, wood, or other materials.

[0142] In addition, referring again to Figure 1. the formliner 100 can comprise a plurality of rib openings 180. The rib openings 180 can be positioned along the ribs 102 of the rib structure of the formhner 100. The location of the openings 180 can correspond to a location of a corresponding rib of another formliner to which the formliner 100 is interconnected. The rib openings 180 can facilitate precise alignment of a plurality of formliners. Further, the rib openings 180 can further contribute to the natural appearance of the faux brick pattern created in the concrete structure. The formation and configuration of πb openings 180 is shown and described further below.

[0143] Figure 4 is a top view of a formliner 200 in accordance with an embodiment. As with the formliner 100, the formlmer 200 comprises a plurality of ribs 202 that form a ribs structure. The ribs 202 can comprise one or more overlapping portions 204 and one or more overlapped portions 206. Additionally, the formliner 200 can comprise non- overlap portions 208. The embodiment of Figure 4 illustrates that the overlapping portions 204 and the non-overlap portions 208 can define a common outer dimension 1. Thus, when a plurality of the formliners 200 are interconnected, the overlapping portions 204 overlap with the overlapped portions 206 and the resulting rib structure of the interconnected formliners has a common outer dimension 1.

|0144] In this regard, as discussed above, the overlapped portions 206 can define an outer dimension 2. The outer dimension 2 can be less than the outer dimension 1. Further, an inner dimension of the overlapping portions 204 can also be greater than the outer dimension 2 of the overlapped portions 206.

[0145} Moreover, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 200 can be configured to define a sub-overlapped section 210. As illustrated in the upper and lower right corners of the formliner 200, the sub-overlapped sections 210 can define an outer dimension 3. The outer dimension 3 can be less than the outer dimension 2 and the outer dimension 1. Further, an inner dimension of the overlapped portions 206 can also be greater than the outer dimension 3 of the sub-overlapped portions 210. Additionally, as described above with respect to Figure 1 , the formliner 200 can also be configured to include a plurality of rib openings 220. As similarly described above, the plurality of nb openings 220 can be located and configured to correspond with corresponding ribs of adjacent interconnected formliners.

[0146] In this manner, a single configuration of a formliner can be used to create a continuous decorative pattern that can be used for any size concrete structure. Advantageously, in contrast to prior art formliners, embodiments of the formliners disclosed herein can be interconnected to create a dimensionally continuous, precise assembly of foπnliners.

(0147] Referring now to Figure 5, an end view of the sub-overlapped section 210 of Figure 4 is illustrated. As shown, the sub-overlapped section 210 defines an outer dimension 3 that is less than the outer dimension 2 of the overlapped section 206 (shown in dashed lines). Additionally, the outer dimension 1 of the overlapping sections 204 is also shown dashed lines and illustrated as being greater than both the outer dimension 2 and the outer dimension 3.

|0148] Figure 6 is a perspective view of the formliner assembly of Figure 2. In particular, the formliner 122 and the formliner 120 are shown in a pre-assembled state. In this regard, Figure 6 illustrates that the overlapped sections 146 of the formliner 120 are received within cavities of the overlapping sections 144 of the formliner 122. As discussed below in reference to Figure 10, the upper surfaces of the overlapping sections 144 of the formliner 122 can be generally flush with the upper surfaces of non-overlap sections 148 of the formliner 120.

[0149] Figure 7 is a partial perspective view of the formliner 200. illustrating the sub-overlapped portion 210 thereof. As shown, the sub-overlapped portion 210 defines a smaller cross-sectional profile or dimension than the overlapped portion 206.

|0150] Figure 8 is a perspective view of the formliner assembly of Figure 2 illustrating the formliners 120, 122, and 124. In this view, the ribs structure of the formliner 120 comprises overlapping portions 300. overlapped portions 302, and a sub-overlapped portion 304. The formliner 124 is first placed onto the overlapped portion 302 of the formliner 120. As can be appreciated, an overlapping portion 310 of the formliner 124 is placed onto an overlapped portion 302 of the formliner 120. Additionally, an overlapped portion 312 (shown as a T-connection) of the formliner 124 is placed onto the sub- overlapped portion 304 of the foπnliner 120. Finally, overlapping portions 320 of the formliner 122 are placed onto the overlapped portions 302 of the foπnliner 120 and the overlapped portion 312 of the formliner 124.

|0151] One of the unique features of embodiments disclosed herein is the inclusion of rib openings that allow the overlapped portions of the ribs to be nested within overlapping portions of other ribs and to extend through the πb openings. For example, with reference to Figure 6. rib openings 150 can be provided in the overlapping sections 144 of the formliner 122. Further, with regard to Figure 8, a rib opening 322 is provided in the overlapping portions 320 of the formliner 122. This rib opening 322 allows the overlapping portions 320 to be overlaid onto the overlapped portion 312 with the overlapped portion 312 extending through the rib opening 322. Similarly, a rib opening 324 allows the overlapped portions 302 the past therethrough thus enabling the overlapping portions 320 to be overlaid onto the overlapped portions 302. Finally, the illustrated embodiment in Figure 8 also shows a rib opening 326 formed in the overlapped portion 312, which enables the sub-overlapped portion 304 to extend therethrough. As will be appreciated by one of skill in the art, the rib openings of some embodiments disclosed herein uniquely allow overlapping formliners to minimize visible seaming by allowing the overlapping portions of the formliners to fit tightly and closely together.

[0152] With reference to Figure 8, once assembled, the overlapping portions 300. 310. and 320 each define a common outer dimension or shape. Thus, when the formhner assembly is pressed into an exposed surface of fresh concrete or when concrete is poured thereagainst. the impressions of the rib structure of the formliner assembly will appear seamless and uniform.

[0153J In addition, as will be appreciated, once the formhners 120. 122, and 124 are assembled, an edge 330 of the overlapping portion 310 of the formliner 124 will be disposed into a corner 332 formed between the overlapped portion 302 and a cell 334 of the formliner 120. As such, any seaming between the overlapping portion 310 of the formliner 124 and the cell 334 of the formliner 120 will be reduced and/or eliminated.

[0154] Similarly, an edge 340 of the overlapping portion 320 of the formliner 122 will be disposed into a comer 342 formed by the overlapped portion 302 and the cell 334. Thus, seaming between the formliner 120 and formbner 122 will be greatly reduced and/or eliminated.

|0155] Figure 9 illustrates many of the above-discussed principles. In this figure, a first formliner 400 is mated with a second formliner 402. And overlapping portion 406 of the first formliner 400 is placed onto an overlapped portion 408 of the second formliner 402. As discussed above with respect to Figure 8, the mating of an edge 410 of the overlapping portion 406 with 412 of the second formliner 402 can create an imperceptible seam between the first and second formliners 400, 402. Further, transition zones or joints 420 between the overlapping portion 406 of the first formliner 400 and an overlapping portion 422 of the second foπnliner 402 can be minimized so as to reduce andVor eliminate any visible seaming at the transition zones or joints 420. [0156] Referring now to Figure 10, an enlarged view of a transition zone or joint 420 of Figure 9 is illustrated. As shown, the transition zone or joint 420 can comprise a simple step 430 from a first dimension to a second dimension. In some embodiments, this may be an immediate increase in the dimension along the rib of the second formliner, specifically from the overlapped portion 408 to the overlapping portion 422. However, in other embodiments, it is contemplated that the step 430 can be a tapered transition between the overlapped portion 408 in the overlapping portion 422. Additionally, a side edge 432 of the overlapping portion 406 of the first formliner 400 can be configured to correspond to the shape and dimension of the step 430.

[0157] Further, Figure 10 also illustrates the nesting arrangement of the overlapping portion 406 of the first formliner 400 is shown with respect to the overlapped portion 408 of the second formliner 402. Finally, Figure 10 also illustrates the orientation of the edge 410 of the overlapping portion 406 of the formliner 400 is shown with respect to the cell 412 of the second formliner 402.

10158] With continued reference to Figure 10. it will be appreciated that a seam 440 formed between the edge 410 and the cell 412 can be reduced as the fit between the first formliner 400 and the second formliner 402 are optimized. In this regard, the internal geometry of the overlapping portion 406 can be specifically configured to match the external geometry of the overlapped portion 408, thus reducing any seam (whether along the edge 410 or the side edge 432) between the overlapping portion 406 and the overlapped portion 408.

J0159] As noted above, one of the advantages of embodiments disclosed herein is that seams of overlapped portions of adjacent formliners can be minimized and/or eliminated. In this regard, as illustrated in Figure 10, the seam 440 is created along a corner at or along a bottom portion of the cell 412 of the formliner 402 which forms part of a prepared formliner mold cavity. In this regard, the seam 440 is positioned such that the weight of a curable material, such as concrete, against the first formliner 400 causes the overlapping portion 406 of the first formliner 400 to be pressed against the overlapped portion 408 of the second formliner 402 with great force thereby causing the edge 410 to be positioned as close as possible relative to the cell 412 in order to minimize and/or eliminate the seam 440 between the adjacent formliners 400. 402. This innovative feature of embodiments disclosed herein, which allows seams to be created along the bottom faces or portions of the mold allows the weight of the curable material to act as a compressive agent in reducing and/or eliminating seams between adjacent formliners. For example, a common curable material such as concrete generally weighs 150 pounds per cubic foot, and embodiments of the present inventions are able to take advantage of the significant force of such a materia] in order to create an aesthetically superior product.

[0160] Furthermore, the tolerances between the overlapping portion 406 and the overlapped portion 408 can also define a seam 442. Specifically, the distance between the edge 432 and the step 430 can define the seam 442. It is contemplated that the overlapping portion 406 can be toleranced with a longitudinal length such that the edge 432 thereof abuts the step 430. It is also contemplated that as with the seam 440, the compressive forces of the material against the first formliner 400 and the second formliner 402 can serve to reduce the size of the seam 442 to thereby create a superior finished product.

[0161] Referring now to Figures 1 -10, it is noted that the above-discussed embodiments of the formliner and formliner components provide for a distinct shelf or step between rib sections having differing geometries or configurations. For example, as noted above with respect to Figure 10, the step 430 is a transition zone, shelf, or shoulder between the overlapping portion 422 and the overlapped portion 408 of the second formliner 402. as briefly mentioned above, the step 430 can provide a gradual transition from the overlapping portion 422 to the overlapped portion 408.however, in some embodiments, it is contemplated that the formliner can be formed with ribs or ridges that taper from a first geometry or configuration to a second geometry or configuration. As such, the shoulder 430 can be eliminated from such embodiments.

[0162] For example, referring generally to a side view similar to that of Figure 30, it is contemplated that a rib can taper from a first dimension or configuration in an overlapping portion to a second dimension or configuration in an overlapped portion. In yet other embodiments, it is contemplated that the rib can taper from the second dimension or configuration to a third dimension or configuration. The tapering of the rib from one dimension to another can comprise a generally constant taper or a variable taper. JOl 63] Further, in some embodiments, overlapping portions of the ribs of the formϋner can be configured to define a variable thickness corresponding to the tapering of the overlapped portions onto which the overlapping portions will be overlaid. As such, the cumulative dimension or configuration of nested or overlaid rib portions can be generally constant. Howevei . it is likewise contemplated that the thickness of overlapping or interconnecting formliners can be generally constant along their respective ribs or ridges.

10164] Additionally, in accordance with at least one of the embodiments disclosed herein is the realization that in forming a pattern of interconnected formliners. the edges along the top. bottom, left, and πght sides of a pattern or casting can be carefully arranged m order to ensure a natural appearance. Commonly, a plurality of formliners must be used in order to form a pattern or casting larger than a few square feet in size. Typically, in arranging or interconnecting the formliners, an artisan may begin from a top left corner and work down and across toward the bottom right corner. Thus, the left side and the top side of the pattern or casting can generally be comprised of whole or entire formhners that are interconnected vertically and horizontally. Additionally, formliners located in the center portions of the pattern or casting are also whole or entire formliners. However, according to at least one of the embodiments disclosed herein is the realization that formhners located along the bottom and right sides of the pattern or casting may only be partial sheets. In some embodiments, this deficiency can be overcome by providing alternative embodiments of a formliner that enable the artisan to create desirable bottom and right side edges and/or that can be interconnected with other formliners along a partial length thereof in order to form a clean edge, whether it is a straight edge, curved edge, angled edge, or otherwise.

[0165] Accordingly, referring to Figures 1 1 -14, alternative formliner embodiments are shown. In Figure 1 1 , a formliner end portion 500 is shown. The formliner end portion 500 can comprise many of the same features as discussed above with respect to the other formliner embodiments. However, the formliner end portion 500 can also optionally comprise a generally straight side 502 that is configured to mate with a corresponding formliner end portion. In this regard, it is contemplated that in use, the formliner end portion 500 can be used at a far side or end of the desired pattern. For example, the formliner end portion 500 can be used for a left side boundary or a right side boundary.

[0166] In some embodiments, the formliner end portion 500 can be configured to mate with another formliner to form a corner of a pattern, casting, or formwork. In such an embodiment, the formhner end portion 500 can also optionally comprise a ledge recess 522, as described below. For example, the ledge recess 522 can be forwarded by a length of the ribs 504 which comprises a reduced geometry or dimension, as shown m dashed lines m Figure ] 1. Accordingly, some embodiments of the formliner end portion 500 can be provided in which the side 502 can mate with corresponding formliner components or portions.

[0167] For example, an exemplary mating arrangement of the formliner end portion 500 with a formliner component or portion is illustrated in Figure 12. As shown therein, the formliner end portion 500 can receive a corresponding formliner end portion 510. The formliner end portion 500 and the corresponding formliner end portion 510 can be interconnected or positioned such that they form a corner in a pattern, casting, or formwork

J0168] In accordance with the embodiments of the formliner end portion 500 and the corresponding formliner end portion 510 illustrated in Figure 12, the corresponding formliner end portion 510 can define a plurality of recesses 512 formed at the ends of rib members 514. The recesses 512 can be configured to allow the rib members 514 to fit over the ribs 504 of the foπnliner end portion 500. Thus, the formliner end portion 500 and the corresponding formliner end portion 510 can be positioned relative to each other at a right angle such that a right angle corner in the pattern or casting is produced. However, it is contemplated that the recesses 512 can define other shapes that allowed the corresponding formliner end portion 510 to be oriented at any variety of angles relative to the formliner end portion 500. In this regard, the side 502 can be oπented generally perpendicularly relative to the ribs 504, or the side 502 can be disposed at an angle relative to the ribs 504, thereby facilitating a desired angular interconnection between the formlincr end portion 500 and the corresponding foπnliner and portion 510.

[0169] Additionally, in the embodiments illustrated in Figure 12, the corresponding formliner end portion 510 can also comprise a mating ledge 520. In some embodiments, the mating ledge 520 can be connected to both the ribs 514 and the planar portions of the cells above the corresponding formliner end portion 510. As such, the mating ledge 520 could be generally rigidly positioned relative to the ribs 514. Such an embodiment could be advantageous in facilitating the alignment between the formliner end portion 500 and the corresponding formliner end portion 510. In this regard, as mentioned above with respect to the side 502, the mating ledge 520 can be oriented at a given angle relative to the ribs 514. As illustrated, the mating ledge 520 can be oriented at approximately a right angle relative to the ribs 514. However, it is contemplated that the mating ledge 520 can also be oriented at any variety of angles relative to the ribs 514. In some embodiments, the mating ledge 520 can be configured to fit into or be received in the ledge recess 522 formed along the formliner and portion 500.

[0170] However, in other embodiments, the mating ledge 520 can be hingedly or moveably attached to the corresponding formliner end portion 510. For example, the mating ledge 520 can be attached to the corresponding formliner end portion 510 along the length of the cells thereof, but not connected to the ribs 514. In other words, the mating ledge 520 can be separated or cut from the ribs 514 by means of a slit 530. Thus, the slit 530 can allow the mating ledge 520 to be generally flexible or movable relative to the corresponding formliner end portion 510. In such embodiments, the mating ledge 520 can be folded under a portion of the formliner end portion 500. Optionally, the side 502 of the formliner and portion 500 can be eliminated in order to allow the mating ledge 520 to extend to underneath the formliner end portion 500.

10171] However, in other embodiments, such as that illustrated in Figure 13, it is contemplated that the ledge recess can be eliminated and that the ribs define a generally constant cross-sectional geometry. For example, the cross-sectional geometry of the ribs can be generally constant along centra) portions and end portions of the ribs adjacent the side of the fonnliner end portion.

(0172] Referring to Figure 13, a formliner end portion 550 can comprise one or more ribs 552. Optionally, the formliner end portion can also comprise a side 554. However, as described above, the side 554 can also be eliminated in some embodiments. Additionally, the corresponding formliner end portion 560 can be configured to mate with the formliner end portion 550. The embodiment of the corresponding formliner and portion 560 does not include the mating ledge of the embodiment discussed m regard to Figure 12. As will be appreciated with reference to Figure 13, openings 562 in ribs 564 of the corresponding formliner end portion 560 can be mated against the ribs 522 of the formliner end portion 550 to create a comer of a desired angle measurement for a pattern or casting. Further, the openings 562 are preferably configured such that an edge 566 of the corresponding formliner end portion 560 can be positioned against the top surface of the cells of the formliner end portion 550 Optionally, the openings 562 can be configured to be manipulated in order to allow varying angles of orientation between the formliner end portion 550 and the corresponding formliner end portion 560 For example, a portion of the ribs 564 can be configured as a "tear away" that allows the openings 562 to be enlarged. The embodiment of Figure 13 can facilitate a tight fit between the formliner end portion 550 and the corresponding formliner end portion 560.

|0173) Referring to Figure 14. another embodiment of a formliner end portion 570 can be provided which comprises one or more ribs 572. As noted above, the formliner end portion 570 is an embodiment in which no side is used. Similar to the other embodiments disclosed herein, the formliner end portion 570 can be configured to mate with a corresponding formliner end portion 580 The embodiment of the corresponding formliner and portion 580 does not include the mating ledge of the embodiment discussed in regard to Figure 12. As will be appreciated with reference to Figure 14, openings 582 m πbs 584 of the corresponding formliner end portion 580 can be mated against the ribs 572 of the formliner end portion 570 to create a corner of a desired angle measurement for a pattern or casting.

|0174] Additionally, as illustrated in the embodiment of Figure 14, the corresponding formliner end portion 580 can comprise a flange 586 extending from an edge thereof. The flange 586 can be monolithically formed with the corresponding formliner end portion 580. The flange 586 can be flexible relative to other portions of the corresponding formliner end portion 580. For example, the flange 586 can be folded underneath the formliner end portion 570 when the corresponding formliner end portion 580 is fitted onto the formliner end portion 570. In this manner, the corresponding formliner end portion 580 can be placed against and/or interconnected with the fonnliner end portion 570. Further, in some embodiments it is contemplated that the formliner end portion 570 and the corresponding fonnliner end portion 580 can be attached along the flange 586 by means of an adhesive. The embodiment of Figure 14 can facilitate a tight fit between the formliner end portion 570 and the corresponding formliner end portion 580.

|0175] It is contemplated that the embodiment of Figures 1 1-14 can aid the artisan in creating a dimensionally accurate and seamless corner of a faux brick mold. It is contemplated also that other such features, such as three-point corners, convex arches, and concave arches can be formed using similar principles.

|0176] Further, Figures 15-16 illustrate other embodiments of a formliner, sheet, or panel having other shapes and geometries for imparting different patterns onto the treated or exposed surface. As discussed above, such patterns can be of stone, wood, slate, or other materials. Figure 15 is a representation of a formliner 600 used to produce a stone pattern on an exposed surface six or 50. Figure 16 is a representation of a formliner used to produce a rock pattern on an exposed surface.

[0177] Figure 17 illustrates yet another embodiment of a formliner, sheet, or panel 700 having a pattern configured to provide the appearance of cut stone. As shown therein, first rib portions 702 of the formliner 700 can be configured to define a first geometry or configuration, and second rib portions 704 can define a second geometry or configuration that corresponds to the first geometry or configuration and enables multiple formhners 700 to be interconnected along the rib portions 702, 704.

[0178| In some embodiments, the formliner 700 can comprise one or more third rib portions 706 that can define a third geometry or configuration that corresponds to one of the first and second geometries or configurations. For example, the first rib portion 702, the second πb portion 704, and the third rib portion 706 can allow the fonnliner 700 to be overlaid with other formhners 700 in a similar manner as to the formliner 100 described above, and as shown in Figures 2-10.

[0179] As mentioned above with respect to the embodiments disclosed in Figures 1 -10, the first rib portions 702, the second rib portions 704, and the third read portions 706. can each comprise rib portions having a generally constant geometry or configuration, such as a cross-sectional geometry. However, it is also contemplated that the first rib portions 702, the second rib portions 704, and the third read portions 706 of the formliner 700 can taper from one geometry or configuration to another. In other words, the ribs or ridges of the formliner 700 can taper from the first geometry or configuration to the second geometry or configuration. In yet other embodiments, the ribs or ridges of the formliner 700 can also taper from the second geometry or configuration to the third geometry or configuration. The tapering in any such embodiment can be formed as a constant taper from one geometry or configuration to another, from one corner to another or along lengths of the ribs or ridges. The tapering in other embodiments can also be formed over discrete sections of the ribs or ridges. Accordingly, in such embodiments, the ribs or bridges can be formed without a distinct shelf or step from a given geometry or configuration to another geometry or configuration. Further, it is contemplated that overlapping portions of adjacent formliners can be configured to define variable thicknesses that taper along with the dimension or configuration of that portion of the ribs or ridges.

[0180] Moreover, the formliner 700 can also comprise one or more openings 710 in one or more of the first, second, or third rib portions 702. 704. 706 in order to allow nesting and overlaying of the rib portions with each other, as similarly described above with respect to the embodiments shown in Figures 1 -10. In this manner, a plurality of the formliners 700 can be used to create a desirable cut stone pattern while eliminating any appearance of seaming between the formliner 700.

|0181] Additionally, in accordance various embodiments, no adhesive is required to interconnect a plurality of the fonuliners during set up. As noted above, one of the inventive realizations disclosed herein is that the set up and interconnection of formliners can also be expedited by eliminating the need to apply adhesives to the overlapping joints of interconnected formliners. Thus, the assembly time for a setting up a large pattern of interconnected formliners can be substantially reduced, as welJ as the cost and parts required, by eliminating the need for adhesives.

[0182] In order to provide such a superior benefit, embodiments of the formliners disclosed herein can comprise a snap-fit arrangement that allows overlapping formliners to form an interlocking joint. Thus, the formliners can be securely connected without using adhesives. Further, such embodiments also result in reduced seaming between the formliners where the formliners meet. Furthermore, another of the unique advantages of such an interlocking joint is that the joint is further stabilized and strengthened through the application of force to the overlapping formliners, such as the application of a curable material such as concrete. Therefore, such an interlocking joint not only allows for the elimination of adhesives, but also provides several structural benefits that ultimately create an aesthetically superior product.

[0183] Another unique benefit of embodiments disclosed herein is that the interlocking joint can be formed by encasing a rib or ridge of an overlapped formliner with a rib or πdge of an overlapping formliner. In other words, the rib of the overlapping formliner can comprise a recess or cavity into which the rib of the overlapped formliner can be received. The cavity can comprise an opening that is less than the cross-sectional size or passing profile of the rib of the overlapped formliner. Thus, the opening of the cavity must be expanded when the rib of the overlapped formliner is inserted therein. Such expansion can occur through deflection or elastic deformation of the opening. The rib of the overlapped formliner can be inserted into the cavity until being fully received therein such that the opening of the cavity returns to its normal size, thus collapsing around a lower portion or base of the rib of the overlapped formlmer. In this manner, the rib of the overlapped formliner is encased within the cavity. The term "snap-fit' ^" can refer to the interference fit, deformation, and subsequent collapsing of the opening Io its normal size around the base of the rib of the overlapped formliner. Additionally, the encasing of the rib of the overlapped formiiner thereby prevents horizontal and vertical relative movement between the overlapped and overlapping formliners.

[0184] In this regard, the interlocking joint and encasing disclosed above is distinct from various other prior art systems, such as that disclosed in U.S. Patent No. 4,858,410, issued to Goldman (hereinafter "Goldman ^"1 ). Figures 18A-C are the original Figures 20-22 taken from the Goldman reference and illustrate a modular brickwork form 802 that is disclosed in Goldman. The brickwork form 802 comprises raised dividers 803 and raised edges 804. A first edge 807 of first form 808 overlaps a second edge 809 of a second form 810. Dimples 806 on the first edge 807 nest within the dimples 806 on the second edge 809 (see Figure 18C). Goldman indicates that the dimples 806 are concave up/convex down depressions on the edge 804 The shape and location of the dimples, raised dividers and edges allow nesting of the forms when stacked. Further, the notches or dimples 806 are also placed to overlap and nest within adjoining dimples {see Figure 18B).

[0185] Figure 18C illustrates a cross-sect ional side view of the dimples 806 of the Goldman brickwork form. Goldman indicates that the forms are stacked such that the first form 808 is placed on top of second form 810. Dividers 806 provide a spacing "a ^" between bricks (see Figure 18B). The dividers and dimpled edges 804 are tapered by an angle ^L" b ^" to allow nesting when stacked. The edge dimension "V is slightly smaller than "a ^" and is selected to provide a spaced apart dimension ^L "a ^" between adjoining bricks when first form 808 is placed on top of the second form 810. The depth "d ^" of dimples 806 is a function of the need to retain adjoining forms. If the foπns are to be laid out on a flat horizontal surface. the dimples function only as locators, requiring a nominal projection into the adjoining edge. The depth "d ^" of the preferred embodiment m this case is less than 3 cm (0.125 inches) m comparison to the overall raised edge dimension "e ^" which is approximately 9 cm (0.375 inches).

|0186] Thus, although the Goldman reference discloses a brickwork form with dimples, the dimples thereof do not comprise any protrusion or detent, for example, to interlock the dimples 806 of the first form 808 with the dimples of the second form 810. The dimples 806 serve only a locating function when positioning the forms to align the πdges of the forms relative to each other. However, the dimples can easily be dislodged or shifted. Further, it is apparent that loading on the edges of the forms can create deformation of the edges. Because the dimples do not serve to restrict separation between the foπns in a vertical direction, such loading can cause the foπns to be disengaged and become misaligned. The dimples simply do not interlock the forms or provide any meaningful engagement between the forms that can eliminate the need for adhesives. Indeed, adhesives are required in order to properly adjoin the forms disclosed in the Goldman reference.

JOl 87] In contrast, embodiments disclosed herein provide a secure interconnection and engagement between overlapping formliners. For example, as discussed herein, an embodiment of the formliner can comprise a protrusion and a detent such that a plurality of formliners can be interconnected with the protrusions engaging respective detents such that the formliners are not only restrained in a horizontal direction, but also in a vertical direction. As such, these features can effectively eliminate the need for glues and adhesives required by inferior prior art designs. The Goldman reference simply does not disclose such features and provides no teaching or suggestion of such features.

[0188] Embodiments of the formliner and formliner components disclosed herein can be manufactured using any of a variety of processes. For example, it is contemplated that some embodiments can be formed using a sheet and a vacuum forming operation. Other manufacturing processes such as injection molding, stamping, extrusion, etc. can also be used.

[0189] With reference now to Figures 19-35, Figure 19 is a perspective view of an embodiment of a formliner. panel, or sheet 1100 in accordance with an embodiment of the present inventions. The formliner 1 300 can comprise a plurality of ribs, ridges, or channels 1102. The ribs 1102 can be a raised portion of the formliner 1100. The ribs 1 102 can define an outer perimeter of the formliner 1 100. Additionally, the ribs 1 102 can extend inwardly to form one or more cells or recesses 1 104.

[0190] In some embodiments, the cells 1 104 can comprise a recessed portion of the formliner 1 100. The recessed portion of the cell 1 104 can be configured to receive a curable material to which a pattern of the formliner can be conferred or transferred. The cells 1104 can be uniformly sized. For example, the cells 1104 can be rectangularly shaped. As discussed below, embodiments of the formliner 1 100 can implement other shapes, depths. and sizes of the cells 1 104.

[0191] As illustrated in the embodiment of Figure 19, the cells or recesses 1 104 can be arranged in rows. As will be discussed further below, the cells or recesses 1 104 of a given row can be offset with respect to cells or recesses of an adjacent or neighboring row. In this regard, a plurality of fonnliners 1100 can be interconnected along ends thereof in such a way as to reduce any visible appearance of a seam between interconnected formliners. The offset configuration of the cells or recesses 1 104 in some embodiments can aid in concealing or hiding any seaming between formliners. [0192] Additionally, the embodiment illustrated in Figure 19 illustrates that the cells 1 104 of adjacent rows can be offset from each other such that at opposing ends of the foπnliner 1 100, some of the cells 1 104 protrude at the end. In this regard, the rows can be formed to include projecting and non-projecting cells 1 104. The projecting cells can be considered to be complete or whole cells. In other words, the projecting cells are not smaller than other cells 1 104 of the pattern even though the offset configuration of the cells 1 104 causes the projecting cells to protrude at one side or end of the formiiner 1 100. As will be discussed further below, the projecting cells of the pattern can be interconnected with projecting cells of another formiiner.

[0193] The embodiment illustrated in Figure 19 can be used to create a faux brick pattern on a concrete structure. The formiiner 1 100 can define a pane] periphery bounding the plurality of cells 1 104 by a plurality of sides. The foπnliner 1 100 defines an upper surface 1 1 10. Although not shown in Figure 19, the formiiner 1 100 also defines a lower surface In use, the upper surface 1 1 10 of the formiiner 1 100 would be positioned such that it can be pressed into fresh concrete. This can be accomplished by placing the upper surface 1 1 10 of the formiiner 1 100 against an exposed surface of fresh concrete. Otherwise, this can be accomplished by affixing the lower surface of the formiiner 1 100 to an interior wall of a pattern, casting, or formwork before concrete is poured into the pattern, casting, or formwork. In either case, a material, such as concrete can be placed against the decorative pattern of the formiiner 1 100 defined by the ribs 1 102 and the cells 1 104 in order to transfer the decorative pattern to the exposed surface of the material as the material cures.

[0194] Jn many cases, the exposed surface of a given structure, such as a wall, walking area, or the like, consists of a large surface area. In order to cover the entire area, several formliners must be used. As shown in the formiiner assembly of Figure 20, several formliners 1 120, 1 122, and 1 124 can be interconnected in order to transfer a decorative pattern onto a large surface area. The interconnection of these foπnlmers 1 120. 1 122, and 1 124 provides a distinct advantage over prior art to formliners because the seams between the formliners 1 120. 1 122, and 1 124 are insubstantial and/or eliminated compared to prior art formliners.

„44.... |0195] As discussed above, Figure 20 illustrates that the formliner 1 120 can comprise projecting cells 1 125 in the formliner 1122 can comprise one or more projecting cells 1126. These projecting cells 1 125. 1 126 can be positioned in different rooms of the formliners 1 120, 1122. Thus, the projecting cells 1 125 can be positioned adjacent to non- projecting cells of the formliner 1 122 in the projecting cell 1 126 can be positioned adjacent to a non-projecting cell of the formliner 1 120. Thus, the cells of the formliner 1120 can be offset with respect to each other and with respect to cells above the formliner 1122. Moreover, the interconnection of the formliners 1 120, 1 122 can be accomplished using offset projecting cells 1 125, 1 126.

[0196] In accordance with some embodiments, the formliner 1 100 illustrated in Figure 19 can be configured such that a plurality of formliners 1 100 can be interconnected at their top and bottom ends and sides. Figure 20 illustrates this principle. The formliners 1120, 1 122, and 1 124 can be interconnected and overlap each other. This interconnection allows the formliners to be easily handled and assembled to a given size. Importantly however, the formliner is configured such that portions thereof can overlap and create a generally uniform and seamless rib structure on the upper surface 11 10 of the foπnliners 3 120, 1 122, and 1124. In other words, the shape and depth of the rib structure formed in the exposed surface of the concrete structure can be generally constant and the transition from a given formliner to another given formliner can be generally imperceptible.

[0197) Moreover, in some embodiments, edges of each of the respective formliners 1120. 1122, and 1 124 can lie along a corner or edge feature of the decorative pattern. As such, when a curable material is placed in against the formliners and takes the shape, in this case of a rectangle having right-angle corners, an edge 1 127 of the formliner 1 122 forms a portion of the corner of the molded or formed rectangle and becomes nearly imperceptible. Accordingly, the overlapping edges 1 127 of the formliner 1 122 create minimal visible seaming, if at all, between the formliners 1120 and 1 122. This principle is illustrated in greater detail in Figures 25-28.

[0198] Additionally, transition zones or joints 1 128 are formed where upper surfaces of ribs the formliners 1 120, 1122, and 1 124 meet. In this regard, the transition zones or joints 1328 can be toleranced in order to define an extremely narrow gap between interconnected formhners. Thus, any seaming at the transition zones or joints 1 128 can also be greatly reduced in order to reduce and/or eliminate visible seaming.

{0199] In this regard, the formliner 1 100 can be configured such that the plurality of ribs 1 102 includes one or more overlapping portions 1 130 and one or more overlapped portions 1132. The overlapping portions 1 130 can be configured to include an internal cavity with an internal geometry that accommodates the external geometry of the overlapped portions 1132. Thus, the overlapped portions 1 132 can be received within the internal cavities of the overlapping portions 1 130.

|0200] The formliner 1 100 can be configured to comprise a protrusion and a detent in order to facilitate interconnection between a plurality of formliners. For example, the ribs 1 102 can be configured to comprise one or more protrusions 1 136 and/or detents 1 138. In some embodiments, as shown in Figures 19 and 2 IA-C, the protrusion 1136 and/or the detent 3 138 can be disposed on the πb 1 102. The protrusion 1 136 and/or detent 1 138 can extend along less than the entire length of a respective rib 1 102 such that the protrusion 1 136 and/or detent 1 138 is offset from a corner or end of the respective rib. Indeed, a series of the protrusions 1 136 and/or detents 1 138 can extend along a length of the rib, with a series of breaks between respective protrusions 1 136 and/or detents 1 138.

[0201] For example, the protrusion 1 136 can be disposed on overlapping portions 1 130 of the rib 1 J 02, and the detent 1 138 can be disposed on overlapped portions 1 132 of the rib 1 102. As such, when the formliner 1 100 is interconnected with other formliners. as shown in Figure 20, the protrusions and the detents can engage each other to interlock the formliners in an assembled state Due to the supeπor engagement created by the protrusions and detents, no adhesives need be used to secure the formliners to each other. Thus, the assembled formlmer system can be placed in a form and a curable material can be placed thereon without worry of having the edges or nbs of the formliners become disengaged from each other. Moreover, no adhesive is required for such exceptional performance. As noted above, these advantages are not present or taught in the prior art.

|0202] In some embodiments, the plurality of ribs 1 102 of the formliner 1 100 can be configured to comprise one or more non-overlap portions 1 134. The non-overlap portions 1 134 can extend between overlapping portions 1 130 and overlapped portions 1 132. However, the non-overlap portions 1134 will not overlap or be overlapped by portions of another formliner win a plurality of formhners are interconnected. When a plurality of formliners is interconnected, the external surface of the overlapping portions 1 130 can be flush with the external surface of the non-overlap portions 1 134.

[0203] An illustration of this principle is shown in Figures 2 IA-C and 24 and described below. Figure 21A it is a cross-sectional side view taken along Section 21A-21A of Figure 20. Figure 20 illustrates that a right side 1 140 of the formliner 1 120 overlaps with a left side 1 142 of the formliner 1 122.

[0204] In Figure 2 ] A, an overlapping portion 1 144 of the formliner 1 122 rests on top of an overlapped portion 146 of the formliner 1 120. The cross-sectional side view also illustrates a cell 1 150 of the formliner 1 120. Further, the formliners 1 120, 1 122 are configured such that the overlapping portion 3 144 of the formliner 1 122 defines an outer surface that matches an outer surface of the ribs 1 102 of the form liners 1 320, 1 122. and 1 124. In other words, the overlapping portions of a formliner can have an outer dimension that is equal to an outer dimension of the non-overlap portions of the ribs of the formliner Thus, the overall rib structure of interconnected formliners will seem continuous in shape and dimension because the overlapping portions and the non-overlap portions (and not the overlapped portions) of the ribs of the formliners are the only portions of the ribs that are exposed.

[0205] In addition, as discussed below with regard to Figure 29. one of the significant advantages of embodiments disclosed herein is that they are able to reduce and/or eliminate seams between adjacent formliners using the significant compressive stresses created by the weight of a curable material, such as concrete, poured onto a formliner assembly or formliner mold cavity. In other words, the configuration of the overlapped and overlapping portions of adjacent formliners enabled the weight of the material to press down upon the overlapping portions of a formlmer in order to optimize the fit between overlapping portions and overlapped portions of adjacent formliners to thereby reduce any visible seaming between the formliners.

[0206] Figure 23 A also illustrates that in some embodiments, the overlapping portions 1 144 can comprise the protrusions 1 136 that engage with detents 1 138 of the overlapped portions 1 146. In the embodiment illustrated in Figures 2 I A-C. the protrusions 1 136 and the detents 1 138 can define a generally trapezoidal cross-sectional profile. However, as described below, the protrusions and detents in some embodiments can define a variety of cross-sexual profiles. Further, Figure 21A indicates that in some embodiments, the ribs of the formliners 1 120, 1 122, 1 124 can each comprise free side edges and corner portions wherealong the rib interconnects with the cell of the formliner. For example, the ribs of the formhner 1 120 can comprise a corner portion 3 170 and a free side edge 1 172. Additionally, the ribs of the formliner 1 122 can comprise a corner portion 1 174 and a free side edge 1 176 Likewise, the ribs of the formliner 1 124 can also comprise a corner portion and a free side edge.

(0207] As illustrated, some embodiments can be configured such that the corner portions of the ribs are formed to include a protrusion or a detent. Similarly, embodiments can be configured such that the free side edges are formed to include a protrusion or a detent. The arrangement of the protrusions and detents along the corner portions or free side edges can be determined based on the pattern, for example. However, as shown in Figure 2 IB, in some embodiments, if the rib portion of the formliner 1 120 is configured to be overlapped by the πb portion of formliner 1122, and therefore of a smaller profile, the comer portion 1 170 of that πb portion and the free side edge 1172 can each comprise a detent 1 138. Further, if a rib portion of the foπnliner 1 122 is configured to be overlapping the rib portion of the formliner 1 320, and is therefore of a larger profile, the corner portion 1 174 and the cancel free side edge 1 176 can each comprise a protrusion 1 136. However, although the rib portions are shown as comprising a pair of protrusions or detents disposed on opposing sides of the rib portion (whether overlapping or overlapped), it is also contemplated that a single protrusion or detent can be used on a side of the πb portion (whether overlapping or overlapped). Further, it is contemplated that m some embodiments, the overlapped portion of the nb (such as the rib of the formlϊner 120) can contact only a portion of the internal surface of the overlapping portion of the rib (such as the rib of the formliner 122). In this regard, some embodiments can be configured such that the interlocking or overlapping of the formliners can be accomplished by complete or partial surface contact between the external and internal surfaces of overlapping rib portions. [0208] In this regard, one of the unique features of some embodiments disclosed herein is that an overlapping rib can define a recess or interior cavity whereinto an overlapped rib of an adjacent formliner can be placed. However, in order to insert the overlapped rib into the recess or interior cavity, an opening of the recess can be expanded to receive the overlapped rib. For example, Figure 21C illustrates that a recess 1 180 of a rib 1 178 of formliner 1 122 comprises an inner diameter, profile, or dimension 1 182 that is sufficiently large to accommodate the outer diameter, profile, or dimension 1 184 of a rib 1 179 of the formliner 1 120. However, the recess 1 180 comprises an opening 1 186 having a passing profile or width 1 188 that is less than the outer diameter, profile, or dimension 1 1 84 of the rib 1179 of the formliner 1 120. Thus, the rib 1 179 of the formliner 1 120 must cause the opening 1186 to expand in order to be fitted within the recess 3 180. Further, the rib 1 179 can comprise a base profile 1 190 that is less than the passing profile or width 1 188 of the rib 1 178. In this regard, once the rib 1 179 of the formliner 1 120 is received into the recess 1 J 80 of the rib 1 178 of the formliner 1 122, the opening 1 186 can converge or snap onto the base profile 1 190 of the rib 1 179, as shown in Figure 2 I B.

|0209] Further, the formliner 1 122 can be fabricated from a resilient material such that after the rib of the formliner 1 120 is inserted within the cavity 1 180, the opening 1 180 elastically returns to its onginal dimension 1 188. In this manner, the opening 1 180 closes around a base of the rib of the formliner 1 120. In other words, with the rib of the formliner 1 120 received within the recess 1 180, the width 1 388 of the opening 1 180 will return to less than the outer diameter, profile, or dimension 3 184 of the rib of the formliner 1 120. thus encasing the rib within the recess 1 180. This is shown in Figure 2 IB. Further, as noted herein, such encasing or snap-fit between the ribs allows the formliner 1 122 to restrict not only horizontal, but also vertical movement of the formliner 1 120 with respect to the formliner 1 122.

[0210] The protrusions and the detents can be configured to extend inwardly toward an interior of the rib. It is contemplated that in some implementations, the protrusions and detents can be formed into the formliner during the molding process. For example, the formliner can be vacuum formed with such features included therein. However, it is also contemplated that the protrusions and detents can be formed subsequent to the initial forming operations. Further, although the protrusions and detents can be formed integrally with the formliner, such as by forming the formliner and protrusions and detents of a common sheet of material, these features could potentially be added to the formliner in a finishing step.

[0211] Referring again to Figure 2 IA, the rib structure of the formliners 1120, 1122 can be generally defined by a semicylindrical or arch shape. Accordingly, the overlapping portions 1144 and the overlapped portions 1 146 can be defined by a radius. In particular, a lower surface 1 160 of the overlapping portion 1 144 of the formliner 1122 can be defined by a first radius. Similarly, an upper surface 1 162 of the overlapped portion 1146 of the formliner 1120 can be defined by a second radius. The first radius can be greater than the second radius in order to allow the overlapped portion 1 146 to be nested within the overlapping portion 1 144. As such, the overlapped portions 1 146 can define a smaller cross- sectional profile than the interior cavity of the overlapping portions 1 144.

[0212] Furthermore, although the rib structure is illustrated as being formed by semicylindrical or arch shaped channels, the rib structure can be formed by a generally rectangular or polygonal cross-section, to provide the appearance of a ^v 'rake joint." In this regard, any variety of shapes can be used. For example, while an embodiment of the formliners discussed herein is generally intended to create an appearance of faux brick, other embodiments of the formliners disclosed herein can be designed to create an appearance of faux stone, including any of various commercial stone such as cut stone, castle rock, sand stone, ledgestone, fieldstone, etc., as well as, wood, river rock, slate, or other materials and variations, which is merely an exemplary and non-limiting list of potential appearances and applications. Thus, the πb structure can be varied and diverse. The dimensions of the rib structure can be variable and allow for irregular patterns as may be seen in natural settings of stone, brick, wood, or other materials.

[0213] For example, referring now to Figure 22A. the rib structure in some embodiments can be configured to define arcuate protrusions and detents formed therealong. This type of structure is often referred to in masonry as a "tool joint." Figure 22A illustrates an overlapping rib 1 192 having a pair of opposing protrusions 1 194 and an overlapped rib 1 196 having a pair of opposing detents 1 198 that are configured to receive the protrusions 1 194 of the rib 1192. The protrusions 1194 and the detents 1198 can comprise a shape that is formed using a transition between convex and concave. In some embodiments, the configuration can be described as an "S ^" shape. In this regard, the arcuate shape of the surfaces can facilitate interlocking between the ribs 1 192, 1 196. Further, as illustrated therein, the protrusions 1 194 and the recesses 1 198 can be configured to extend inwardly to a lesser degree than the embodiment shown in Figures 21 A-C. Accordingly, it is contemplated that the embodiment of the rib structure shown in Figure 22A can be substituted for that shown in Figures 2 IA-C and implemented with the embodiments of the formlϊners disclosed herein.

|0214] Figure 22B is an enlarged cross-sectional side view of another embodiment of a formliner. In the embodiment illustrated in Figure 22B, the nb structure of the formliner is provided with a polygonal geometry to provide the appearance of a "rake joint," mentioned above. As illustrated, an overlapped rib 1250 can comprise a generally trapezoidal cross- sect ion. The overlapped rib 1250 can define an external geometry or profile that is less than an internal geometry or profile of an overlapping rib 1252. In this regard, the overlapping rib 1252 can be overlaid onto the overlapped rib 3250, as illustrated. In the illustrated embodiment, the overlapped rib 1250 generally makes contact with the internal surface of the overlapping rib 1252. However, in accordance with some of the embodiments disclosed herein, it is contemplated that the overlapped rib 1250 contact only a portion of the internal surface of the overlapping rib J 252.

[0215] Figure 22C is an enlarged cross-sectional side view of another embodiment of a formliner. Similar to the embodiment illustrated in Figure 22B, the embodiment shown in Figure 22C can provide the appearance of a "rake joint." However, in addition to the aesthetic distinction, the embodiment in Figure 22C can also provide enhanced engagement through the use of protrusions and recesses. As illustrated, an overlapped rib 1260 can comprise one or more recesses 1262. In the illustrated embodiment, the recesses 1262 can be oriented along a lower portion or lower edge of the rib 1260. However, as with other embodiments disclosed herein, the recesses can be disposed on other portions of the rib. Referring again to Figure 22C, and overlapping rib 1270 can comprise one or more protrusions 1272 that can engage the one or more recesses 1262. In this manner, when the overlapping rib 1270 is overlaid onto the overlapped rib 1260, the protrusions 1272 can engage the recesses 1262 in order to facilitate interlocking engagement between the ribs 1260, 1270 of the formliners. As noted herein, this interlocking engagement provides several advantages in assembling and using the formliners.

|0216} Ln addition, referring again to Figure 19, the formlmer 1 100 can comprise a plurality of rib openings 1 180. The rib openings 1 180 can be positioned along the ribs 1 102 of the rib structure of the formliner 1 100. The location of the openings 1 180 can correspond to a location of a corresponding rib of another formliner to which the formliner 1100 is interconnected. The rib openings 1 180 can facilitate precise alignment of a plurality of formliners. Further, the rib openings 1 180 can further contribute to the natural appearance of the faux brick pattern created in the concrete structure. The formation and configuration of rib openings 1 180 is shown and described further below.

[0217] Various methods are also provided for manufacturing embodiments of the formliners disclosed herein. Generally, many of the embodiments disclosed herein can be manufactured using material to formation processes such as vacuum or thermoforming, injection molding, and other such processes. Thermoforming with the vacuum assist can be used to achieve superior results for thick or thin gauge formliners.

[0218] As will be appreciated by one of skill in the art, the thermoforming process begins with a blank that is heated and placed over a mold. Often, a mating mold can be placed over the heated blank to trap the blank between the mold and the mating mold. Vacuum pressure can also be applied to remove any air between the mold and the blank and thereby further draw the blank into the mold.

[0219] In accordance with a unique aspect of some of the methods disclosed herein, the formed sheet can be formed to include excess material length. For example, referring to Figure 36 below, a formliner 1800 is shown in a nearly completed state. As shown, the foπnliner 1800 can include πb protrusions 1804 that can extend from the left and/or πght sides of a formliner 1800. In this manner, using a subsequent cutting step, the rib protrusions 1804 can be removed or trimmed such that the left and/or right sides of the formliner 1800 are prepared to receive or be overlaid with other formliners. The trimming of the rib protrusions 1804 can be used to create one or more rib openings discussed above. In this manner, the initial forming operation can be simplified while allowing a precise edge to be cut in order to define the rib openings. Therefore, in accordance with some embodiments disclosed herein, the forming step can comprise forming one or more rib protrusions in the formed sheet during manufacturing of the formliner. Subsequently, the method of manufacturing the formhner can comprise trimming or otherwise removing the one or more rib protrusions from the formliner in order to define one or more rib openings.

[0220] Once a blank has been formed into a formed sheet using a thermoforming machine, the formed sheet can be further processed using cutting equipment. Ln some embodiments, the process can employ a laser-cutting device. A laser can provide superior results by exact dimensioning and tolerancing; however, other cutting devices can also be used. The cutting operation or step allows the rib openings discussed above to be formed for those embodiments in which rib openings are used. However, in all embodiments, the cutting operation or step can be used to remove excess material from the edges of the formed sheet in order to produce a prepared formliner. The cutting operation or step can be particularly important in order to ensure that mating edges properly align with corresponding portions of other foπnliners. Additionally, the cutting operation or step can be particularly important in ensuring that protrusions and recesses of formhners can be properly engaged in assembling a plurality of formliners.

[0221] Figure 23 is a top view of a formliner 1200 in accordance with an embodiment. As with the formliner 1100, the foπnliner 1200 comprises a plurality of ribs 1202 that form a rib structure. The ribs 1202 can comprise one or more overlapping portions 1204 and one or more overlapped portions 1206. Additionally, the formliner 3200 can comprise non-overlap portions 1208. The embodiment of Figure 23 illustrates that the overlapping portions 1204 and the non-overlap portions 1208 can define a common outer dimension 1001. Thus, when a plurality of the formliners 1200 are interconnected, the overlapping portions 1204 overlap with the overlapped portions 1206 and the resulting rib structure of the interconnected formliners has a common outer dimension 1001. Further, the protrusions and detents can be placed on a single side or both sides of a peripheral rib. in accordance with some embodiments.

[0222] In this regard, as discussed above, the overlapped portions 1206 can define an outer dimension 1002. The outer dimension 1002 can be less than the outer dimension 1001. Further, an inner dimension of the overlapping portions 1204 can also be greater than the outer dimension 1002 of the overlapped portions 1206.

[0223] Moreover, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 1200 can be configured to define a sub -overlapped section 1210. As illustrated in the upper and lower right corners of the formliner 1200, the sub-overlapped sections 1210 can define an outer dimension 1003. The outer dimension 1003 can be less than the outer dimension 1002 and the outer dimension 1001. Further, an inner dimension of the overlapped portions 1206 can also be greater than the outer dimension 1003 of the sub-overlapped portions 1210. Additionally, as described above with respect to Figure 19, the formliner 1200 can also be configured to include a plurality of rib openings 1220. As similarly described above, the plurality of πb openings 1220 can be located and configured to correspond with corresponding ribs of adjacent interconnected formliners.

[0224] As noted above, in some embodiments, the overlapped portions can comprise one or more detents, and the overlapping portions can comprise one or more protrusions. In this regard, it is contemplated the protrusions and detents can extend along any length of a respective rib For example, the protrusions and detents can extend along less than the entire length of a respective rib such that the protrusion and/or detent is offset from a corner or end of the respective rib. It is also contemplated that the piotrusions and detents can extend continuously or discontinuously along the lespective πb. Moreover, it is appreciated that the design and interlocking profile of the formliner can dictate the arrangement, length, and pattern of the protrusions and detents.

[0225] In this manner, a single formhner can be used to create a continuous decorative pattern that can be used for any size concrete structure. Advantageously, in contrast to pπor art formliners, embodiments of the formliners disclosed herein can be interconnected to create a dimensionally continuous, precise assembly of formliners.

[0226] Referring now to Figure 24, an end view of the sub-overlapped section 1210 of Figure 23 is illustrated. As shown, the sub-overlapped section 1210 defines an outer dimension 1003 that is less than the outer dimension 1002 of the overlapped section 1206 (shown in dashed lines). Additionally, the outer dimension 1001 of the overlapping sections 1204 is also shown dashed lines and illustrated as being greater than both the outer dimension 1002 and the outer dimension 1003.

[0227 j Figure 25 is a perspective view of the formliner assembly of Figure 20. In particular, the formliner 1122 and the formliner 1120 are shown in a pre-assembled state In this regard, Figure 25 illustrates that the overlapped sections 1146 of the formliner 1 120 are received within cavities of the overlapping sections 1144 of the formliner 1122. As discussed below in reference to Figure 29, the upper surfaces of the overlapping sections 1 144 of the formliner 1122 can be generally flush with the upper surfaces of non-overlap sections 1 148 of the formliner ] 120.

[0228] Figure 25 also illustrates another view of the engagement between the protrusions 1 136 formed on the free side edges 1 176 and the corner portions 1 174 of the overlapping sections 1 144 of the formliner 1 122 and the detents ) 138 formed on the free side edges 1172 and the corner portions 1 170 of the overlapped sections 1146 of the formliner 1 120. As shown therein, the corner portions of the rib are formed wherealong the rib and the cell meet.

J0229] Figure 26 is a partial perspective view of the formliner 1200. illustrating the sub-overlapped portion 1210 thereof. As shown, the sub-overlapped portion 1210 defines a smaller cross-sectional profile or dimension than the overlapped portion 1206. Figure 26 also illustrated detents 1212 formed along comer portions 1214 and outer side edges 1216 of the formliner 1200.

|0230] Figure 27 is a perspective view of the formliner assembly of Figure 20 illustrating the fbrmliners 1120, J 122. and 1 124. In this view, the πbs structure of the formliner 1120 comprises overlapping portions 1300, overlapped portions 1302, and a sub- overlapped portion 1304. The formliner 1 124 is first placed onto the overlapped portion 1302 of the formliner 1 120. As can be appreciated, an overlapping portion 1310 of the fonnliner 1 124 is placed onto an overlapped portion 1302 of the formliner 1 120. Additionally, an overlapped portion 1312 (shown as a T-connection) of the formliner 1 124 is placed onto the sub-overlapped portion 1304 of the formliner 1 120. Finally, overlapping portions 1320 of the formliner 1122 are placed onto the overlapped portions 1302 of the formliner 1120 and the overlapped portion 1312 of the formliner 3 124.

[0231] One of the unique features of embodiments disclosed herein is the inclusion of rib openings that allow the overlapped portions of the nbs to be nested within overlapping portions of other ribs and to extend through the rib openings. For example, with reference to Figure 25, rib openings 1150 can be provided in the overlapping sections 3 144 of the fonnlmer 1 122. Further, with regard to Figure 24, a rib opening 1322 is provided in the overlapping portions 1320 of the formliner 1 122. This rib opening 1322 allows the overlapping portions 1320 to be overlaid onto the overlapped portion 1312 with the overlapped portion 1312 extending through the rib opening 1322. Similarly, a rib opening 1324 allows the overlapped portions 1302 the past therethrough thus enabling the overlapping portions 1320 to be overlaid onto the overlapped portions 1302. Finally, the illustrated embodiment in Figure 8 also shows a rib opening 1326 formed in the overlapped portion 1312, which enables the sub- overlapped portion 1304 to extend therethrough. As will be appreciated by one of skill in the art, the rib openings of some embodiments disclosed herein uniquely allow overlapping formiiners to minimize visible seaming by allowing the overlapping portions of the foπnliners to fit tightly and closely together.

[0232] With regard to Figure 27. once assembled, the overlapping portions 1300, 1310, and 1320 each define a common outer dimension or shape. Thus, when the formliner assembly is pressed into fresh concrete or when concrete is poured thereagamst, the impressions of the rib structure of the formliner assembly will appear seamless and uniform.

[0233] In addition, as will be appreciated, once the formhners 1 120. 1 122, and 1124 are assembled, an edge 1330 of the overlapping portion 1310 of the formliner 1124 will be disposed into a corner 1332 formed between the overlapped portion 1302 and a cell 1334 of the formliner 1 120. As such, any seaming between the overlapping portion 1310 of the formliner 1 124 and the cell 1334 of the formliner 1 320 will be reduced and/or eliminated.

[0234] Similarly, an edge 1340 of the overlapping portion 1320 of the formliner 1122 will be disposed into a corner 1342 formed by the overlapped portion 1302 and the cell 1334. Thus, seaming between the formliner 1 120 and formliner 1122 will be greatly reduced and/or eliminated. j 0235] Further, the seaming can further be reduced in some embodiments wherein the formliners 1 120, 1 122, 1 124 comprise detents and protrusions that facilitate engagement between the formliners 1 120, 1122, 1 124. As illustrated, the formlmer 1 120 can comprise detents 1350 that can be engaged by protrusions 1352 of the formliner 1 124. Further, the formliner 1 120 can comprise detents 1354 that can be engaged by protrusions 1356 of the formlmer 1 122. Finally, the formliner 1124 can comprise detents 1358 that can be engaged by protrusions 1360 of the formliner 1122.

|0236] Figure 28 illustrates many of the above-discussed principles. In this figure- a first formliner 1400 is mated with a second foπnhner 1402. And overlapping portion 1406 of the first formhner 1400 is placed onto an overlapped portion 1408 of the second formliner 1402. As discussed above with respect to Figure 27. the mating of an edge 14] 0 of the overlapping portion 1406 with 1412 of the second formliner 1402 can create an imperceptible seam between the first and second formliners 1400. 1402. Further, transition zones or joints 1420 between the overlapping portion 1406 of the first formhner 1400 and an overlapping portion 1422 of the second formliner 1402 can be minimized so as to reduce and/or eliminate any visible seaming at the transition zones or joints 1420.

[0237] Furthermore, upon application of a curable material to the formliner assembly illustrated in Figures 28 and 29, protrusions 1424 of the overlapping portion 1406 of the first formliner 1400 can be further engaged with detents 1426 of the overlapped portions 1408 of the second formliner 1402. This enhanced engagement further prevents dislodging or misalignment between the formliners 3400, 1402. Again, such a superior benefit is not disclosed or taught by prior art formliners.

|0238] Referring now to Figure 29, an enlarged view of a transition zone or joint 1420 of Figure 28 is illustrated. As shown, the transition zone or joint 1420 can comprise a simple step 1430 from a first dimension to a second dimension. In some embodiments, this may be an immediate increase in the dimension along the rib of the second formliner, specifically from the overlapped portion 1408 to the overlapping portion 1422. However, in other embodiments, it is contemplated that the step 1430 can be a tapered transition between the overlapped portion 3408 and the overlapping portion 1422. Additionally, a side edge 1432 of the overlapping portion 1406 of the first formliner 1400 can be configured to correspond to the shape and dimension of the step 1430.

[0239] Further, Figure 29 also illustrates the nesting arrangement of the overlapping portion 1406 of the first formliner 1400 is shown with respect to the overlapped portion 1408 of the second formliner 1402. Finally, Figure 29 also illustrates the orientation of the edge 1410 of the overlapping portion 3406 of the foπnliner 1400 is shown with respect to the cell 1412 of the second foπnliner 1402.

|0240] With continued reference to Figure 29, it will be appreciated that a seam 1440 formed between the edge 1410 and the cell 1412 can be reduced as the fit between the first formliner 1400 and the second formliner 1402 are optimized. In this regard, the internal geometry of the overlapping portion 1406 can be specifically configured to match the external geometry of the overlapped portion 1408. thus reducing any seam (whether along the edge 1410 or the side edge 1432) between the overlapping portion 1406 and the overlapped portion 1408.

[0241} As noted above, one of the advantages of embodiments disclosed herein is that seams of overlapped portions of adjacent formliners can be minimized and/or eliminated. Ln this regard, as illustrated in Figure 29, the seam 1440 is created along a corner at or along a bottom portion of the cell 1412 of the formliner 1402 which forms part of a prepared formliner mold cavity. In this regard, the seam 1440 is positioned such that the weight of a curable material, such as concrete, against the first formliner 1400 causes the overlapping portion 1406 of the first formliner 1400 to be pressed against the overlapped portion 1408 of the second foπnliner 1402 with great force thereby causing the edge 1410 to be positioned as close as possible relative to the cell 1432 in order to minimize and/or eliminate the seam 1440 between the adjacent foπnliners 1400, 1402. This innovative feature of embodiments disclosed herein, which allows seams to be created along the bottom faces or portions of the mold allows the weight of the curable material to act as a compressive agent in reducing and/or eliminating seams between adjacent formliners. For example, a common curable material such as concrete generally weighs 150 pounds per cubic foot, and embodiments of the present inventions are able to take advantage of the significant force of such a material in order to create an aesthetically superior product. [0242) Furthermore, the tolerances between the overlapping portion 1406 and the overlapped portion 1408 can also define a seam 1442. Specifically, the distance between the edge 1432 and the step 1430 can define the seam 1442. It is contemplated that the overlapping portion 1406 can be toleranced with a longitudinal length such that the edge 1432 thereof abuts the step 1430. It is also contemplated that as with the seam 1440, the compressive forces of the material against the first formliner 1400 and the second formliner 1402 can serve to reduce the size of the seam 1442 to thereby create a superior finished product.

[0243] Referring now to Figures 19-29, it is noted that the above-discussed embodiments of the formliner and formHner components provide for a distinct shelf or step between rib sections having differing geometries or configurations. For example, as noted above with respect to Figure 29, the step 1430 is a transition zone, shelf, or shoulder between the overlapping portion 1422 and the overlapped portion 1408 of the second formliner 1402 as briefly mentioned above, the step 1430 can provide a gradual transition from the overlapping portion 1422 to the overlapped portion 1408.however, in some embodiments, it is contemplated that the formliner can be formed with ribs or ridges that taper from a first geometry or configuration to a second geometry or configuration. As such, the shoulder 1430 can be eliminated from such embodiments.

[0244] For example, referring generally to a side view similar to that of Figure 29, it is contemplated that a rib can taper from a first dimension or configuration in an overlapping portion to a second dimension or configuration in an overlapped portion. In yet other embodiments, it is contemplated that the rib can taper from the second dimension or configuration to a third dimension or configuration. The tapering of the rib from one dimension to another can comprise a generally constant taper or a variable taper.

[0245] Further, in some embodiments, overlapping portions of the ribs of the formliner can be configured to define a variable thickness corresponding to the tapering of the overlapped portions onto which the overlapping portions will be overlaid. As such, the cumulative dimension or configuration of nested or overlaid rib portions can be generally constant. However, it is likewise contemplated that the thickness of overlapping or interconnecting formliners can be generally constant along their respective ribs or ridges. |0246] Additionally, in accordance with at least one of the embodiments disclosed herein is the realization that in forming a pattern of interconnected formhners. the edges along the top, bottom, left, and right sides of a pattern or casting can be carefully arranged in order to ensure a natural appearance. Commonly, a plurality of formhners must be used in order to form a pattern or casting larger than a few square feet in size. Typically, in arranging or interconnecting the formhners, an artisan may begin from a top left corner and work down and across toward the bottom right corner. Thus, the left side and the top side of the pattern or casting can generally be comprised of whole or entire formliners that are interconnected vertically and horizontally. Additionally, formliners located in the center portions of the pattern or casting are also whole or entire formliners. However, according to at least one of the embodiments disclosed herein is the realization that formliners located along the bottom and right sides of the pattern or casting may only be partial sheets, In some embodiments, this deficiency can be overcome by providing alternative embodiments of a formhner that enable the artisan to create desirable bottom and right side edges and/or that can be interconnected with other formliners along a partial length thereof in order to form a clean edge, whether it is a straight edge, curved edge, angled edge, or otherwise.

|0247] Accordingly, referring to Figures 30-33, alternative formliner embodiments are shown, hi Figure 30, a formliner end portion 1500 is shown. The formliner end portion 1500 can comprise many of the same features as discussed above with respect to the other formliner embodiments. For example, the formliner end portion 1500 can comprise the protrusions and/or detents discussed above. However, the formhner end portion 1500 can also optionally comprise a generally straight side 1502 that is configured to mate with a corresponding formliner end portion. In this regard, it is contemplated that in use. the formliner end portion 1500 can be used at a far side or end of the desired pattern. For example, the formliner end portion 1500 can be used for a left side boundary or a right side boundary.

10248] In some embodiments, the formhner end portion 1500 can be configured to mate with another formliner to form a corner of a pattern, casting, or formwork. In such an embodiment, the formliner end portion 1500 can also optionally comprise a ledge recess 1522, as described below. For example, the ledge recess 1522 can be forwarded by a length of the ribs 1504 which comprises a reduced geometry or dimension, as shown in dashed lines in Figure 30. Accordingly, some embodiments of the formhner end portion 1500 can be provided in which the side 1502 can mate with corresponding formliner components or portions.

[0249] For example, an exemplary mating arrangement of the formliner end portion 1500 with a formliner component or portion is illustrated in Figure 31. As shown therein, the formliner end portion 1500 can receive a corresponding formliner end portion 1510. The formliner end portion 1500 and the corresponding formliner end portion 1510 can be interconnected or positioned such that they form a corner in a pattern, casting, or formwork.

[0250] In accordance with the embodiments of the formliner end portion 1500 and the corresponding formliner end portion 1510 illustrated in Figure 31 , the corresponding formliner end portion 1510 can define a plurality of iecesses 1512 formed at the ends of rib members 1514. The recesses 1512 can be configured to allow the πb members 1514 to fit over the πbs 1504 of the formliner end portion 1500. Thus, the formlmer end portion 1500 and the corresponding formliner end portion 1510 can be positioned relative to each other at a right angle such that a right angle comer in the pattern or casting is produced. However, it is contemplated that the recesses 1512 can define other shapes that allowed the corresponding formliner end portion 1510 to be oπented at any variety of angles relative to the formliner end portion 1500. In this regard, the side 1502 can be oriented generally perpendicularly relative to the ribs 1504. or the side 1502 can be disposed at an angle relative to the ribs 1504, thereby facilitating a desired angular interconnection between the formliner end portion ] 500 and the corresponding formliner and portion 1530.

[0251] Additionally, in the embodiments illustrated in Figure 3I ₃ the corresponding formliner end portion 1510 can also comprise a mating ledge 1520. In some embodiments, the mating ledge 1520 can be connected to both the πbs 1514 and the planar portions of the cells above the corresponding foπnliner end portion 1510. As such, the mating ledge 1520 could be generally rigidly positioned relative to the ribs 1514. Such an embodiment could be advantageous m facilitating the alignment between the formliner end portion 1500 and the corresponding formliner end portion 1510. In this regard, as mentioned above with respect to the side 1502, the mating ledge 1520 can be oriented at a given angle relative to the ribs 1514. As illustrated, the mating ledge 1520 can be oriented at approximately a right angle relative to the ribs 1514. However, it is contemplated that the mating ledge 1520 can also be oriented at any variety of angles relative to the ribs 1514. In some embodiments, the mating ledge 1520 can be configured to fit into or be received in the ledge recess 1522 formed along the formliner and portion 1500.

|0252] However, in other embodiments, the mating ledge 1520 can be hingedly or moveably attached to the corresponding formliner end portion 1510. For example, the mating ledge 1520 can be attached to the corresponding formliner end portion 1510 along the length of the cells thereof, but not connected to the ribs 1514. In other words, the mating ledge 1520 can be separated or cut from the ribs 1514 by means of a slit 1530. Thus, the slit 1530 can allow the mating ledge 1520 to be generally flexible or movable relative to the corresponding formliner end portion 1510. hi such embodiments, the mating ledge 1520 can be folded under a portion of the formliner end portion 1500. Optionally, the side 1502 of the formliner and portion 1500 can be eliminated in order to allow the mating ledge 1520 to extend to underneath the formliner end portion 1500.

|0253] Nevertheless, in other embodiments, such as that illustrated in Figure 32, it is contemplated that the ledge recess can be eliminated and that the ribs define a generally constant cross-sectional geometry. For example, the cross-sectional geometry of the ribs can be generally constant along central portions and end portions of the ribs adjacent the side of the formliner end portion.

|0254] Further, as shown in Figure 31, in some embodiments, the formliner end portion 1510 can comprise one or more protrusions 1540 disposed at the recesses 1512 for engaging corresponding detents 1542 formed in the ribs 1504. As such, the interconnection of the formliner end portions 1500, 1510 can be sufficiently secure so as not to require an adhesive.

[0255] Referring to Figure 32, a formliner end portion 1550 can comprise one or more ribs 1552. Optionally, the formliner end portion can also comprise a side 1554. However, as described above, the side 1554 can also be eliminated in some embodiments. Additionally, the corresponding formliner end portion 1560 can be configured to mate with the formlϊner end portion 1550. The embodiment of the corresponding formliner and portion 1560 does not include the mating ledge of the embodiment discussed in regard to Figure 31. As will be appreciated with reference to Figure 32, openings 1562 in ribs 1564 of the corresponding formliner end portion 1560 can be mated against the ribs 1522 of the formliner end portion 1550 to create a corner of a desired angle measurement for a pattern or casting. Further, the openings 3562 are preferably configured such that an edge 3566 of the corresponding formliner end portion 1560 can be positioned against the top surface of the cells of the formliner end portion 1550. Optionally, the openings 1562 can be configured to be manipulated in order to allow varying angles of orientation between the formliner end portion 1550 and the corresponding formliner end portion 1560. For example, a portion of the ribs 1564 can be configured as a "tear away ^" that allows the openings 1562 to be enlarged. The embodiment of Figure 32 can facilitate a tight fit between the formliner end portion 1550 and the corresponding formliner end portion 1560.

[0256] Further, as shown in Figure 32, in some embodiments, the formliner end portion 1560 can comprise one or more protrusions 1572 disposed at the recesses 1562 for engaging corresponding detents 1574 formed in the ribs 1522. As such, the interconnection of the formliner end portions 1550, 1560 can be sufficiently secure so as not to require an adhesive.

[0257] Referring to Figure 33, another embodiment of a formliner end portion 1570 can be provided which comprises one or more ribs 1572. As noted above, the formliner end portion 1570 is an embodiment in which no side is used. Similar to the other embodiments disclosed herein, the formliner end portion 1570 can be configured to mate with a corresponding formliner end portion 1580. The embodiment of the corresponding formhner and portion 1580 does not include the mating ledge of the embodiment discussed m regard to Figure 31. As will be appreciated with reference to Figure 33, openings 1582 in ribs 1584 of the corresponding formliner end portion 1580 can be mated against the ribs 1572 of the formliner end portion 1570 to create a corner of a desired angle measurement for a pattern or casting.

[0258] It is contemplated that the embodiment of Figures 30-32 can aid the artisan in creating a dimensionally accurate and seamless corner of a faux brick mold. It is contemplated also that other such features, such as three-point comers, convex arches, and concave arches can be formed using similar principles.

[0259] Further, Figures 33-34 illustrate other embodiments of a formliner, sheet, or panel having other shapes and geometries for imparting different patterns to a curable material. As discussed above, such patterns can be of stone, wood, slate, or other materials. Figure 33 is a representation of a fbrmlϊner 1600 used to produce a stone pattern on an exposed surface. Figure 34 is a representation of a formhner 1650 used to produce a rock pattern on an exposed surface. As discussed herein, the formliners 1600, 1650 can also be formed to include one or more protrusions and/or detents for enhancing engagement of interconnected formliners so as to eliminate the need for adhesives.

[0260] Figure 35 illustrates yet another embodiment of a formliner, sheet, or panel 1700 having a pattern configured to provide the appearance of cut stone. As shown therein, first rib portions 1702 of the formliner 1700 can be configured to define a first geometry or configuration, and second rib portions 1704 can define a second geometry or configuration that corresponds to the first geometry or configuration and enables multiple formliners 1700 to be interconnected along the rib portions 1702, 1704.

[0261] In some embodiments, the formliner 1700 can comprise one or more third rib portions 1706 that can define a third geometry or configuration that corresponds to one of the first and second geometries or configurations. For example, the first rib portion 1702. the second πb portion 1704, and the third rib portion 1706 can allow the formliner 1700 to be overlaid with other formliners 1700 in a similar manner as to the formliner 1100 described above, and as shown in Figures 20-29.

[0262] As mentioned above with respect to the embodiments disclosed in Figures 19-29, the first rib portions 1702, the second rib portions 1704, and the third rib portions 1706, can each comprise rib portions having a generally constant geometry or configuration, such as a cross-sectional geometry. However, it is also contemplated that the first rib portions 1702, the second rib portions 1704, and the third read portions 1706 of the formliner 1700 can taper from one geometry or configuration to another. In other words, the ribs or ridges of the formliner 1700 can taper from the first geometry or configuration to the second geometry or configuration. In yet other embodiments, the ribs or ridges of the formliner 1700 can also taper from the second geometry or configuration to the third geometry or configuration. The tapenng in any such embodiment can be formed as a constant taper from one geometry or configuration to another, from one corner to another or along lengths of the ribs or ridges. The tapering in other embodiments can also be formed over discrete sections of the ribs or ridges. Accordingly, in such embodiments, the ribs or bridges can be formed without a distinct shelf or step from a given geometry or configuration to another geometry or configuration. Further, it is contemplated that overlapping portions of adjacent formliners can be configured to define variable thicknesses that taper along with the dimension or configuration of that portion of the ribs or ridges.

[0263] Furthermore, the formliner 1700 can comprise one or more detents 1708 and one or more protrusions 1709. As discussed above with respect to the various other embodiments disclosed herein, the protrusions and detents can enhance the interlocking connection between formliners so as to eliminate the need for adhesives.

|0264] Finally, the formliner 1700 can also comprise one or more openings 1710 in one or more of the first, second, or third rib portions 1702, 1704. 1706 in order to allow nesting and overlaying of the rib portions with each other, as similarly described above with respect to the embodiments shown in Figures 19-29. In this manner, a plurality of the formliners 1700 can be used to create a desirable cut stone pattern while eliminating any appearance of seaming between the formliner 1700.

[0265] In accordance with some embodiments, any of the embodiments of the formliner or combinations thereof can be used in a method of creating a decorative pattern in a curable material, such as a casting, whether vertical or horizontal, a wall. etc. The method can comprise assembling a plurality of any of the formliners disclosed herein to form an assembly. Further, a curable material can be positioned against the assembly, such as by pouring. Ln this manner, the seams between portions of adjacent formliners can be lessened due to the weight of the material. As the material cures, the seams between the adjacent formliners are reduced and/or eliminated compared to the prior art methods and formliners. As such, one may obtain an aesthetically superior product. Further, any of the embodiments herein provides the additional benefit that the artisan need not perform additional finishing steps to eliminate unsightly seams, thus resulting in a tremendous cost and time savings and efficiency.

[0266] Figure 36 is a top view of yet another embodiment of an alternative configuration of a formlmer 1800, according to another embodiment. The illustrated embodiment of the formlmer 1800 differs from other embodiments, such as that shown in Figures 1 and 19. For example, the formJiner 1800 comprise a larger number of cells 1802. Accordingly, the formliner 1800 can be interconnected with other such formhners and be utilized to cover large areas more efficiently than a smaller formlmer, such as that shown in Figures 1 and 19.

10267] Additionally, as discussed above, the formhner 1800 is also shown in a nearly finished state. In other words, the formhner 1800 can still be trimmed in order to produce a finished or prepared formhner. In accordance with some embodiments, the formhner 1800 can comprise one or more πb protrusions 1804 that extend from left and/or right sides of the formliner 1800. As discussed above, these rib protrusions 1804 can be removed prior to use in order to form a nb openings, which are discussed above with respect to other embodiments and shown, for example, in at least Figures 6, 8, 19, 23, 25. and 27.

|0268] Further, as in the other embodiments disclosed herein, the formliner 1800 shown m Figure 36 also comprises one or more overlapping portions 1850 and one or more overlapped portions 1852. Additionally, the formhner 1800 can comprise non-overlap portions 1854. The embodiment of Figure 36 illustrates that the overlapping portions 1850 and the non-overlap portions 1854 can define a common outer dimension 1860. Thus, when a plurality of the formliners 1800 are interconnected, the overlapping portions 1 850 overlap with the overlapped portions 1852 and the resulting nb structure of the interconnected formhners has a common outer dimension 1860.

|0269] In this regard, as discussed above, the overlapped portions 1852 can define an outer dimension 1862. The outer dimension 1862 can be less than the outer dimension 1860. Further, an inner dimension of the overlapping portions 1850 can also be greater than the outer dimension 1862 of the overlapped portions 1852.

|0270] Moreover, as discussed above, it is contemplated that in using a formliner that defines a generally rectangular perimeter, there may be sections of interconnected formliners in which more than two formliners overlap. Accordingly, in some embodiments, the formliner 1800 can be configured to define one or more sub-overlapped sections 1870. Similar to the embodiments discussed above, the sub-overlapped sections 1870 can be provided in the upper and lower right corners of the formϋner 1800. Further, the sub- overlapped sections 1870 can define an outer dimension 1872. The outer dimension 1872 can be less than the outer dimension 1862 and the outer dimension 1860. Further, an inner dimension of the overlapped portions 1852 can also be greater than the outer dimension 1870 of the sub-overlapped portions 1870. Additionally, as described above, the formliner 1800 can also be configured to include a plurality of rib openings that are formed upon removal of the πb protrusions 1804. As similarly described above, the plurality of rib openings can be located and configured to correspond with corresponding ribs of adjacent interconnected formliners.

[0271 j In accordance with some embodiments of the formliners disclosed herein, the sub-overlapped section (such as 210, 304, 1210, 1304. and 1870) can also be configured such that a length of the sub-overlapped section, as measured along the longitudinal direction of the rib, varies to provide optimal fit between overlapping formliners. For example, as shown in Figure 36, the sub-overlapped section 1870 can be disposed along a length of the rib, not just at the corner of the formliner. In particular, the sub-overlapped section 1870 can extend along the rib for approximately one-half of the total width of the cell 1802. In other embodiments, it is contemplated that the sub-overlapped section 1870 can extend along the rib for one-fourth or one-third of the total width of the cell 1802. Additionally, in configurations where the cells 1802 are offset, the length of the sub-overlapped section can correspond to the length of the offset of the cell 1802 from the formliner 1800. In other words, the length of the sub-overlapped section can correspond to the amount of protrusion of a cell from the formliner. In this manner, the fit and nesting of the ribs is optimized when a plurality of formliners are fitted together, such as with an overlapping section of a first formliner, an overlapped section of a second formliner, and a sub-overlapped section of a third formliner being overlaid onto each other.

10272] Figure 37 is a top view of a formliner that has been modified to be a mold corner 1900, according to another embodiment. The term "mold corner" or "formliner ^" can be used to describe such embodiments. In the illustrated embodiment, the mold corner 1900 comprises several rows of cells 1902 with only a single cell 1902 per row. Nevertheless, embodiments can be provided that include a plurality of cells 1902 in each row of the mold corner 1900. Additionally, invite immense can also be provided that include more or less rows of cells 1902.

[0273] Similar to the embodiment of Figure 36 discussed above, the mold corner 1900 is also shown in a nearly finished state. In other words, the mold corner 1900 can still be trimmed in order to produce a finished or prepared formliner. In accordance with some embodiments, the mold corner 1900 can comprise one or more rib protrusions 1904 that extend from left and/or right sides of the formliner 1900. As discussed above, these rib protrusions 1904 can be removed prior to use in order to form a rib openings, which are discussed above with respect to other embodiments and shown, for example, in at least Figures 6. 8. 19. 23, 25, and 27.

[0274] In accordance with the embodiment illustrated in Figure 37, the mold corner 1900 can comprise a central folding zone 1910. The mold comer 1900 can be formed such that the central folding zone 3910 comprises a folding line 1912 and such ribs 1914 of the mold corner 1900 include recesses 1916. The mold corner 1900 can be configured to be folded along the central folding zone 1910 such that a rear face of the mold corner 1900 can be positioned against an interior corner of a form. In this regard, the ribs 1914 of the mold corner 1900 can also be formed to include overlapped portions 1920 and overlapping portions 1922. As disclosed generally herein, the overlapped portions 1920 can be received within or made with overlapping portions of one or more other formliners in order to form a system of formliners. Further, the overlapping portions 1922 can be overlaid onto overlapped portions of one or more other formliners in order to form a system of formliners. Other features disclosed with respect to other embodiments can also be incorporated into embodiments of the mold corner 1900, such as sub- overlapped portions, interlocking protrusions and recesses, and other such features.

[0275] One of the unique advantages of the mold corner 1900 is that the mold corner 1900 helps to reduce the number of scenes and components in a system of formliners used to create a final molded product. In this regard, it is contemplated that the mold corner 1900 can be configured to bend along the folding line 1912 to achieve one of a variety of angular orientations between a first portion 1930 and a second portion 1932 of the mold corner 1900. In this regard, the folding line 1912 can be configured as a thinned area of the mold corner 1900. Further, the folding line 1912 can be configured as a perforated area of the mold comer 1900. Furthermore, the folding line 1912 can also be configured as an indented area of the mold corner 1900. Other variations and configurations of the folding line 1912 can be provided in order to facilitate folding of the mold corner 1900 along the folding line 1912.

10276] For example, it is contemplated that the mold corner 1900 can be configured to provide a 90° bend between the first portion 1930 and the second portion 1932. Figure 38A illustrates a top view of a recess 1916 formed in a rib in 1914 of the mold comer 1900. Further, Figure 38B is a side view of the portion of the mold corner 1900 shown in Figure 38A.

[0277] As illustrated in the embodiment of Figures 38A-B, the recess 1916 can comprise a generally 45° angle indentation from a top portion of the rib 1914 downwardly toward the folding line 1912. Accordingly, when the first portion 1930 is folded towards the second portion 1932, interior surfaces 1940, 1942 of the recess 1916 can collapse towards each other and contact each other to complete an interior profile of the folded mold corner 3900. In this regard, the interior surfaces 1940, 1942 can be oriented at first and second angles 1950. 1952 relative to a bottom surface or section of the rib 1914. In the illustrated embodiment, the first and second angles 1950, 1952 are approximately 45°. However, as necessary, other embodiments can be implemented that use greater or lesser angles, thus enabling the first portion 1932 form a variety of different angles relative to the second portion 1932. such that the mold comer 1902 can be used in various applications having a variety of different geometries.

[0278] In some embodiments, as illustrated in Figures 37-38B, upper surfaces of the first and second portions 1930, 1932 can fold inwardly toward each other. As discussed herein, this inward folding is facilitated in some embodiments by the formation of the recess in the rib. However, it is also contemplated that other implementations can be provided in which bottom surfaces of the first and second portions 1930, 1932 fold inwardly toward each other. As such, instead of forming an interior mold corner that is inserted into a corner of a mold (which can constitute an angle of less than 180°), and embodiment of the mold corner can also provide an exterior mold corner that is folded around a corner of a mold (such as folding the bottom surfaces of the first and second portions 1930, 1932 toward each other to accommodate an angle of greater than 180°). In such embodiments, the central folding zone could be reversed so as to provide a continuous upper surface of the rib while providing a recess along a lower portion of the rib and a gap in the material so as to allow the bottom surfaces of the first and second portions 1930, 1932 fold inwardly toward each and be folded around a corner of the mold.

|0279j Referring again to Figure 37, as noted above, the mold corner 1900 can comprise one or more overlapping portions 1922 and one or more overlapped portions 1920. Additionally, the mold corner 1900 can comprise non-overlap portions 1954. The embodiment of Figure 37 illustrates that the overlapping portions 1922 and the non-overlap portions 1954 can define a common outer dimension 1960. Thus, when a plurality of the formliners 1900 are interconnected, the overlapping portions 1922 overlap with the overlapped portions 1920 and the resulting rib structure of the interconnected formliners has a common outer dimension 1960.

10280] In this regard, as discussed above, the overlapped portions 3920 can define an outer dimension 1962. The outer dimension 1962 can be less than the outer dimension 1960. Further, an inner dimension of the overlapping portions 1922 can also be greater than the outer dimension 1962 of the overlapped portions 1920.

[0281] Moreover, as discussed above, it is contemplated that in interconnecting formliners with the mold corner and/or mold corners with mold corners and formliners. there are certain points where one or more formliner(s) overlap with one or more mold corner(s). Accordingly, m some embodiments, the mold corner 1900 can be configured to define one or more sub-overlapped sections 1970. Similar to the embodiments discussed above, the sub- overlapped sections 1970 can be provided in the upper and lower right corners of the mold corner 1900. Further, the sub-overlapped sections 1970 can define an outer dimension 1972. The outer dimension 1972 can be less than the outer dimension 1962 and the outer dimension 1960. Further, an inner dimension of the overlapped portions 1920 can also be greater than the outer dimension 1970 of the sub-overlapped portions 1970. Additionally, as described above, the mold corner 1900 can also be configured to include a plurality of rib openings that are formed upon removal of the πb protrusions 1904. As similarly described above, the plurality of rib openings can be located and configured to correspond with corresponding ribs of adjacent interconnected formhners.

10282] In accordance with some embodiments of the formliners disclosed herein, the sub-overlapped section (such as 210, 304, 1210, 1304, 1870, 1970) can also be configured such that a length of the sub -overlapped section, as measured along the longitudinal direction of the rib, varies to provide optimal fit between overlapping formliner(s)/mold corner(s). For example, as shown in Figure 37, the sub-overlapped section 1970 can be disposed along a length of the rib, not just at the corner of the mold corner. In particular, the sub-overlapped section 1970 can extend along the rib for approximately one- half of the total width of the cell 1902. In other embodiments, it is contemplated that the sub- overlapped section 1970 can extend along the rib for one-fourth or one-third of the total width of the cell 1902. Additionally, m configurations where the cells 1902 are offset, the length of the sub-overlapped section can correspond to the length of the offset of the cell 1902 from the mold comer 1900. In other words, the length of the sub-overlapped section can correspond to the amount of protrusion of a cell from the mold corner. In this manner, the fit and nesting of the nbs is optimized when a plurality of mold corner(s) and/or formhner(s) are fitted together, such as with an overlapping section of a first formliner, an overlapped section of a first mold comer, and a sub-overlapped section of a second mold comer being overlaid onto each other.

|0283] Moreover, the formliners, mold corners, and other components can be formed in any variety of shapes and the ribs or ridges formed in the formliners can serve to provide strength against the weight of the curable material positioned thereagainst without requiring that the formhner be exceedingly bulky, thick, or otherwise heavy. In this regard. embodiments of the formliner can advantageously be used, for example, in tilt-up assemblies that require heavy materials such as rebar without contributing significantly, if even much at all, to the overall weight of the assembly. As such, the formliners allow for the use of less rigorous machinery, such as smaller cranes, etc. Accordingly, the light weight of embodiments of the formhner can allow for additional reductions in cost, time, and labor.

[0284] As discussed above, embodiments of the formliners disclosed herein allows the artisan to eliminate and/or reduce any visible seaming between interconnected formliners. Some embodiments of the formliners disclosed herein are able to effectively eliminate such seaming by converging formliner edges into comers above an interconnected formhner and using tight tolerances in mating exposed surfaces of the interconnected formliners.

|Θ285J Although these inventions have been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present inventions extend beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the inventions and obvious modifications and equivalents thereof. In addition, while several variations of the inventions have been shown and described in detail, other modifications, which are within the scope of these inventions, will be readily apparent to those of skill in the art based upon this disclosure, ϊt is also contemplated that various combination or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the inventions. It should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed inventions. Thus, it is intended that the scope of at least some of the present inventions herein disclosed should not be limited by the particular disclosed embodiments described above.