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.

1 . A reversible liner for imprinting a malleable surface comprising: 
 a top face having a decorative pattern thereon; and    a bottom face having a decorative pattern thereon, such that either the top face or the bottom face may be used to imprint indentations in the malleable surface.    
   
   
       2 . The liner as claimed in  claim 1 , wherein the liner is formed from an extruded polyethylene copolymer material.  
   
   
       3 . The liner as claimed in  claim 1 , wherein the liner has a width of approximately one foot to ten feet and a length of approximately one foot to sixteen feet.  
   
   
       4 . The liner as claimed in  claim 1 , the liner further including opposing end edges and opposing side edges.  
   
   
       5 . The liner as claimed in  claim 4 , wherein the liner is flexible, such that the opposing end edges may contact each other and the opposing side edges may contact each other without damaging the liner.  
   
   
       6 . The liner as claimed in  claim 5 , wherein the top face of the liner provides a protrusion and the bottom face of the liner provides a recess.  
   
   
       7 . The liner as claimed in  claim 1 , wherein an edge of the liner is provided with a flange, such that an open side of a second liner may abut the flange to provide a seamless, contiguous pattern.  
   
   
       8 . In a liner for imprinting a malleable surface, the liner comprising opposing end edges, opposing side edges, and top and bottom faces and having a decorative pattern formed on at least one of the faces, the liner having a Young's modulus in the range of approximately 2.00 (kgf/mm 2 )/(mm/mm) to 4.00 (kgf/mm 2 )/(mm/mm) at approximately 72° F. when having a size of approximately 0.5 inch wide, 0.078 inch thick, and 4 inches long.  
   
   
       9 . The liner as claimed in  claim 8 , wherein the liner can be used to imprint the malleable surface approximately thirty to fifty times.  
   
   
       10 . The liner as claimed in  claim 9 , wherein the liner is reversible, such that a second of the at least one faces has an opposing decorative pattern formed thereon.  
   
   
       11 . The liner as claimed in  claim 10 , wherein for a liner having a size of approximately 1 to 10 feet wide, approximately 1 to 16 feet long, and approximately 0.03 inch to 1 inch thick, the opposing end edges may contact each other and the opposing side edges may contact each other.  
   
   
       12 . The liner as claimed in  claim 11 , wherein the liner may imprint the malleable surface without first being casted onto a board.  
   
   
       13 . A liner having a decorative pattern formed thereon and operable to be bent so as to imprint the decorative pattern on a curved, malleable surface without use of a support board.  
   
   
       14 . The liner as claimed in  claim 13 , wherein the liner is formed from an extruded polyethylene copolymer material.  
   
   
       15 . The liner as claimed in  claim 13 , the liner including opposing end edges and opposing side edges forming closed and open sides, respectively, wherein the first side edge is provided with a flange to form the closed side so that an open side of a second liner may abut the flange to provide a seamless, contiguous pattern  
   
   
       16 . The liner as claimed in  claim 15 , wherein due to the liner's flexibility, the opposing end edges may contact each other and the opposing side edges may contact each other.  
   
   
       17 . The liner as claimed in  claim 16 , wherein the decorative pattern includes a plurality of raised, concave protrusions to imprint simulated mortar joints on the malleable surface.  
   
   
       18 . A flexible liner for imprinting a malleable surface comprising: 
 a top face provided with a decorative pattern that includes a plurality of protrusions;    a bottom face provided with a reflection of the decorative pattern that includes a plurality of recesses;    opposing end edges; and    first and second opposing side edges forming closed and open sides, respectively, wherein the first side edge is provided with a flange to form the closed side so that an open side of a second liner may abut the flange to provide a seamless, contiguous pattern,    wherein the flexible liner may be shaped to imprint the decorative pattern on a curved malleable surface, such that the opposing end edges may contact each other and the opposing side edges may contact each other.    
   
   
       19 . A method of imprinting a decorative pattern on a curved malleable surface comprising the steps of: 
 removably securing a liner providing the decorative pattern to a mold, 
 wherein the mold is operable to receive a wetted flowable material that when hardened produces the imprinted malleable surface, and  
 wherein the mold includes at least one generally curved portion;  
   pouring the wetted flowable material into the mold;    allowing the material to harden into the malleable surface; and    separating the mold and liner removably secured thereto from the surface.    
   
   
       20 . The method as claimed in  claim 19 , wherein the liner includes bottom and top faces, opposing end edges, and opposing side edges.  
   
   
       21 . The method as claimed in  claim 20 , wherein the liner is formed from an extruded polyethylene copolymer material.  
   
   
       22 . The method as claimed in  claim 20 , wherein the liner has a width of approximately one foot to ten feet and a length of approximately one foot to sixteen feet.  
   
   
       23 . The method as claimed in  claim 22 , wherein the liner is flexible, such that the opposing end edges may contact each other and the opposing side edges may contact each other.  
   
   
       24 . The method as claimed in  claim 23 , wherein the top face of the liner provides a protrusion and the bottom face of the liner provides a recess for producing protrusions and recesses on the surface.  
   
   
       25 . The method as claimed in  claim 19 , wherein an edge of the liner is provided with a flange, such that an open side of a second liner may abut the flange to provide a seamless, contiguous pattern.  
   
   
       26 . The method as claimed in  claim 19 , wherein the liner may used to imprint the malleable surface without first being casted onto a board.