Interlocking Formliners for Seamless Concrete Patterns
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Solution Overview
Problem
Existing formliners for creating decorative patterns in concrete often result in visible seams when multiple units are interconnected, compromising the appearance of the finished product and making it costly to remove these seams from cured concrete.
Innovation Solution
The development of an improved formliner with seamlessly connecting components that eliminate the need for adhesives and feature interlocking ridges and cells to nest together, minimizing visible seams and creating a natural appearance by overlaying overlapping sections onto overlapped sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple formliners are connected using butt joints, then the formliners can be assembled to create large patterns, but visible seams are created between the formliners compromising the appearance
Solution Approach 1:
The formliner system is divided into multiple individual formliner units that can be assembled together. Each formliner contains ribs with overlapping sections that interlock with adjacent formliners, allowing the system to cover large areas while maintaining seamless appearance through the overlapping rib design that eliminates visible joints between segments
Solution Approach 2:
The formliners are designed with overlapping rib sections where one formliner's rib overlaps and nests within the rib structure of the adjacent formliner. This nesting arrangement allows the formliners to interconnect while maintaining a continuous, seamless surface that eliminates visible seams between connected units
2Strength
If formliners are connected with adhesives, then the connection between formliners is strengthened, but the complexity and cost of the construction process increases
Solution Approach 1:
The formliners are designed with self-interlocking rib structures that automatically connect adjacent formliners through overlapping sections. The ribs are shaped to fit together without requiring external adhesives or fasteners, allowing the formliners to self-assemble and self-secure while maintaining strong connections and simplifying the construction process
Solution Approach 2:
The design replaces chemical bonding methods (adhesives) with a mechanical interlocking system. The overlapping rib sections create a mechanical connection through friction and geometric interlocking, eliminating the need for adhesives while maintaining connection strength and reducing construction complexity
3Loss of time
If visible seams are left in cured concrete, then the construction time is reduced, but the aesthetic quality and value of the finished product deteriorates
Solution Approach 1:
The formliners are pre-designed with overlapping rib sections that create seamless joints before the concrete is poured. This preliminary design ensures that when the concrete cures and the formliners are removed, no visible seams remain in the finished surface, eliminating the need for post-curing seam removal work and preserving both construction time and aesthetic quality
Data Source
AI summary
Features for formliners to form a decorative pattern in a curable material and methods of using the same are disclosed. An improved formliner is disclosed with seamlessly connecting components that reduces the need for using adhesives for interconnecting a plurality of formliners in a pattern. Further, the formliner is configured to reduce and/or substantially eliminate visible seams in order to create a more natural appearance in a finished product of the curable material.