Overlapping formliner manufacturing process

Abstract

A process of manufacturing an overlapping formliner is disclosed. The process includes applying a formliner material to a mold, the mold having pocket molds for producing formliner pockets and a lattice of ridge molds for producing formliner ridges, then forming the overlapping formliner, the overlapping formliner having a varied ridge width being configured to be positioned to overlap an adjacent formliner, and then demolding the formliner from the mold to produce the formliner having the formliner pockets and the formliner ridges.

What is claimed is: 
     
         1 . A process of manufacturing an overlapping formliner, the process comprising:
 applying a formliner material to a mold, the mold having pocket molds for producing formliner pockets and a lattice of ridge molds for producing formliner ridges; then   forming the overlapping formliner, the overlapping formliner having a varied ridge width being configured to be positioned to overlap an adjacent formliner; and then   demolding the formliner from the mold to produce the formliner having the formliner pockets and the formliner ridges.   
     
     
         2 . The process of  claim 1 , wherein the mold includes a rigid high-density urethane closed cell foam. 
     
     
         3 . The process of  claim 1 , wherein the mold includes a rigid polyisocyanurate foam. 
     
     
         4 . The process of  claim 1 , wherein the overlapping formliner includes an interface to be positioned between the overlapping formliner and the adjacent formliner and reduce leakage of cementitious material. 
     
     
         5 . The process of  claim 1 , wherein the overlapping formliner includes alignment features. 
     
     
         6 . The process of  claim 5 , wherein the alignment features are within the varied ridge width. 
     
     
         7 . The process of  claim 5 , wherein the alignment features provide additional stability during stacking for transport. 
     
     
         8 . The process of  claim 1 , wherein the overlapping formliner includes alignment features on two sides. 
     
     
         9 . The process of  claim 1 , wherein the overlapping formliner includes alignment features on four sides. 
     
     
         10 . The process of  claim 1 , wherein the overlapping formliner and the adjacent formliner are substantially identical. 
     
     
         11 . The process of  claim 1 , wherein the overlapping formliner and the adjacent formliner are substantially different. 
     
     
         12 . The process of  claim 1 , wherein the formliner material includes an elastomeric material. 
     
     
         13 . The process of  claim 1 , wherein the formliner material includes a recycled material. 
     
     
         14 . The process of  claim 1 , wherein the applying of the formliner material includes injecting the formliner material into the mold. 
     
     
         15 . The process of  claim 1 , wherein the applying of the formliner material includes pouring the formliner material into the mold. 
     
     
         16 . The process of  claim 1 , wherein the forming of the overlapping formliner is by injection molding. 
     
     
         17 . The process of  claim 1 , wherein the forming of the overlapping formliner is by thermoforming. 
     
     
         18 . The process of  claim 1 , wherein the mold has pores and the formliner materials does not seep into pores of the mold and bond to the mold. 
     
     
         19 . A process of manufacturing an overlapping formliner, the process comprising:
 injecting or pouring an elastomeric material into a rigid high-density urethane closed cell foam or a rigid polyisocyanurate foam mold having a pocket mold for producing formliner pockets and a lattice of ridge molds for producing formliner ridges; then   forming the overlapping formliner, the overlapping formliner having a varied ridge width being configured to be positioned to overlap an adjacent formliner; and then   demolding the overlapping formliner to produce the formliner having the formliner pockets and the formliner ridges.   
     
     
         20 . A process of manufacturing a formliner, the process comprising:
 applying a formliner material to a mold, the mold having a pocket mold for producing formliner pockets and a lattice of ridge molds for producing formliner ridges; then   forming the overlapping formliner, the overlapping formliner having a varied ridge width being configured to be positioned to overlap an adjacent formliner; and then   demolding the formliner from the mold to produce the formliner having the formliner pockets and the formliner ridges;   wherein the mold includes a rigid high-density urethane closed cell foam or a rigid polyisocyanurate foam.