Interlocking Formliner System for Seamless Concrete Corners
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Solution Overview
Problem
Existing concrete formliners create visible seams when interconnected, compromising the appearance of decorative concrete surfaces and requiring significant time and cost to address these imperfections.
Innovation Solution
The development of a snap-fit formliner system with interlocking components that eliminate the need for adhesives, allowing for seamless connections and reduced seaming, utilizing raised sections and ribs to nest and stabilize the formliners, ensuring a natural appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple formliners are placed together using butt joints, then the formliners can be assembled to create large patterns, but visible seams are created between the formliners
Solution Approach 1:
The formliner design incorporates nested ribs where ribs from adjacent formliners interlock in a nested configuration. One formliner's ribs fit into the spaces between ribs of the adjacent formliner, creating an interlocked arrangement that eliminates gaps and visible seams while allowing large area coverage.
Solution Approach 2:
The solution transitions from two-dimensional butt joint placement to three-dimensional interlocking by adding vertical rib structures that extend upward from the formliner surface. This dimensional addition allows ribs to overlap and interlock in space, eliminating seams through spatial engagement rather than simple edge-to-edge contact.
2Stability of the object's composition
If formliners are interconnected using adhesives, then the formliners can be securely connected, but assembly time and cost increase
Solution Approach 1:
The design replaces the chemical bonding system (adhesives) with a purely mechanical interlocking system. The nested rib structures engage physically through geometric compatibility, providing secure connection through friction and mechanical interlock rather than chemical adhesion, thereby eliminating adhesive application time.
Solution Approach 2:
The formliners are designed to self-connect through their own geometric features. The nested rib structures automatically engage and lock together when formliners are placed adjacent to each other, eliminating the need for external adhesives or additional fastening components. The system serves itself through inherent geometric interlocking.
3Stability of the object's composition
If formliners are interconnected using adhesives, then the formliners can be securely connected, but material cost and complexity increase
Solution Approach 1:
The design replaces the chemical bonding system (adhesives) with a purely mechanical interlocking system. The nested rib structures engage physically through geometric compatibility, providing secure connection through friction and mechanical interlock rather than chemical adhesion, thereby eliminating adhesive application time.
Solution Approach 2:
The rib structures serve multiple functions simultaneously: they provide the decorative surface pattern, create the interlocking mechanism for connection, and establish the nested geometry for seam elimination. This multi-functionality reduces system complexity by consolidating multiple roles into a single structural element.
Data Source
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AI summary
The invention relates to formliners comprising at least two formliners configured to form a corner in curable material when the at least two formliners are assembled together. The formliners comprise a first and a second formliner. The first formliner comprises: a cell comprising a recessed portion, wherein at least a part of the recessed portion is configured contact the curable material; a boundary side extending along at least a part of the cell of the first formliner, the boundary side connected to the cell at a predetermined angle relative to the recessed portion of the cell of the first formliner, the predetermined angle corresponding to a desired angle of the corner in the curable material; and a rib extending along at least a part of the cell of the first formliner toward the boundary side, the rib of the first formliner comprising an exterior surface forming an exterior cross-sectional profile, wherein at least a portion of the exterior surface is configured to contact the curable material. The second formliner comprises: a cell comprising a recessed portion; and a rib extending along at least a part of the cell of the second formliner, the rib of the second formliner comprising an opening having a cross-sectional profile corresponding to the exterior cross-sectional profile of the rib of the first formliner with the second formliner positioned at the predetermined angle relative to the first formliner. The first formliner is configured to be assembled with the second formliner at the predetermined angle to form the corner in the curable material with the desired angle by mating the opening of the rib of the second formliner with exterior surface of the rib of the first formliner with the boundary side of the first formliner contacting the recessed portion of the cell of the second formliner along the predetermined angle relative to the recessed portion of the cell of the first formliner to minimize visible seams in the curable material.