Reversible and flexible liner for imprinting a decorative pattern on a malleable surface and a method of using same

Abstract

A liner for imprinting a decorative pattern on a malleable surface, such as concrete, and a method of doing same, wherein the liner is flexible so as to imprint on curved surfaces and reversible so as to imprint opposing indentations of the decorative pattern. The liner comprises bottom and top faces, opposing side edges, and opposing end edges. Due to the flexibility, the opposing end edges and opposing side edges may contact each other, which allows for the liner to be used in any curved mold for imprinting any curved surface. Due to the reversibility, either protruding or recessed mortar joints may be imprinted on the surface. The method provides for removably securing the liner to the mold; pouring a wetted flowable material into the mold that will harden; and separating the mold and liner combination from the hardened surface.

Description

RELATED APPLICATION [0001] The present application is a continuation-in-part and claims priority benefit, with respect to all common subject matter, of U.S. application Ser. No. 10 / 423,619, filed Apr. 24, 2003, entitled “WALL SYSTEM,” and herein incorporated by reference. U.S. application Ser. No. 10 / 423,619 claims priority benefit of U.S. Provisional Application No. 60 / 375,611, filed Apr. 24, 2002, and entitled “QUICK SET RETAINING WALL,” which is also incorporated into the present application by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to imprinting decorative patterns on malleable surfaces, such as concrete. More particularly, the invention relates to a liner having a decorative pattern formed thereon and for use in lining a form or mold so that wetted concrete poured within the form or mold and allowed to set is imprinted with the decorative pattern. The liner may be used to imprint both vertical and horizontal c...

AI Technical Summary

Benefits of technology

[0017] To form a flat concrete section, the liner is removably secured to a light, fibrous board, and the board and liner combination is positioned within a frame sized to form a concrete section. Wetted, flowable material, such as concrete, is poured on top of the liner and allowed to harden. Once hardened, the concrete section is lifted up, and the board and liner combination is easily removed from the concrete section.

[0018] A liner of a second preferred embodiment is substantially similar to the liner of the first preferred embodiment, except that the liner is used to imprint a curved concrete section. For this embodiment, the liner is preferably secured directly to a mold for the concrete section, such as a SONOTUBE. The mold may be any shape, such as circular, rectangular, etc, so as to form a column or other preferred shape. A location of where end edges of the liner meet is marked. Wetted concrete is poured into the mold and allowed to set. Once hardened, the mold is cut along the marked location so as not to cut the liner. The mold and liner combination easily removes from the concrete section, and the liner is removed from the mold so as to create the column or other shape.

[0019] By constructing a liner as described herein, numerous advantages are realized. For example, the liner of the present invention is flexible enough to imprint curved concrete sections. Additionally, because both faces of the liner are provided with the decorative pattern, the liner may imprint both protruding and recessed joints as dictated by the aesthetic desires of the user. Further, the board and liner combination is light and easily removed from the concrete section. Further yet, the liner of the present invention is approximately ten times less than prior art lines. Prior art liners with the plywood board cost approximately $1200, whereas the liner and board combination of the present invention costs approximately $120.

Problems solved by technology

Although many methods and devices are known for imprinting concrete, most have drawbacks.

The rigid liner is casted to the plywood board during manufacture, such that end users of the liner cannot remove the liner from the plywood board without damaging the liner.

Without the board, prior art liners tear very easily and cannot withstand repeated uses.

Therefore, after the concrete has hardened and the board and liner combination must be removed from the concrete section, a large amount of force, and sometimes tools, must be used to separate the board and liner combination from the concrete section.

Every time the liner is used and subsequently removed from a concrete section, the liner is damaged because the pock marks and indentations tear and are made larger by the required force to separate the liner from the concrete section.

Thus, because the hardened concrete set into the plurality of pock marks and indentations grips the liner and because the board and liner combination is very heavy, the board and liner combination is not easily removed from the concrete section.

Therefore, known prior art liners allow for only imprinting flat sections of concrete, which significantly limits the types or shapes of concrete sections that may be imprinted.

Similarly, the prior art rigid liner does not offer enough flexibility to fold the liner in half, either along the length of the liner or the width of the liner, without permanently damaging the liner.

Although it is rare that the liner would need to be folded in such a manner to imprint the concrete section, such lack of flexibility does severely impede the concrete sections that may be imprinted.

For example, if the concrete section is curved to a degree to which the prior art liner cannot be curved, then the curved concrete section cannot be imprinted with the rigid liner, notwithstanding the fact that the rigid liner is permanently casted to a rigid plywood board.

Another disadvantage of prior art rigid liners is that a pattern is formed on only one face of the liner.

An even further disadvantage of prior art liners is the type of board used on which to mount the liner.

), expensive, and inherently cumbersome to use.

However, such large, thick boards are necessary to provide the needed support for the rigid liner.

The boards have a limited use life due to water from the poured concrete contacting the boards and rotting or otherwise destroying them, requiring disposal of both the boards and liners.

Even if the boards were capable of more uses, the liner itself is usually limited to less than twenty uses.

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