Thermoplastic liner for casting textures and objects into poured wall

Abstract

A formliner can be used to make textures as well as secure and seal objects to form a poured wall. The formliner includes a layer of foam material defining a plurality of object locations separated by raised portions. Each raised portion can define an airspace thereunder.

1 . A formliner for casting objects into a cured wall, the formliner comprising:
 a layer of foam material comprising a plurality of object locations separated by raised portions, each raised portion defining an airspace thereunder.   
     
     
         2 . The formliner of  claim 1 , wherein said raised portions comprise row members and column members, said row members being nonparallel to said column members. 
     
     
         3 . The formliner of  claim 1 , wherein each object location comprises an upper surface having a predetermined height, each raised portion having a height greater than said predetermined height. 
     
     
         4 . The formliner of  claim 3 , wherein each airspace has a height greater than said predetermined height. 
     
     
         5 . The formliner of  claim 1 , wherein said foam material defines an area, said foam material being continuous throughout said area. 
     
     
         6 . The formliner of  claim 1 , wherein a thickness of said foam material comprising a said object location is similar to a thickness of said foam material comprising a said raised portion. 
     
     
         7 . The formliner of  claim 1 , wherein said layer of foam material comprises a constant thickness. 
     
     
         8 . The formliner of  claim 1 , wherein an upper surface of said formliner has no open cells. 
     
     
         9 . The formliner of  claim 1 , wherein each outer surface of said formliner has no open cells. 
     
     
         10 . The formliner of  claim 1 , further comprising a layer of reinforcing material having a yield stress greater than that of said foam material. 
     
     
         11 . The formliner of  claim 10 , wherein said reinforcing material follows contours in said foam material. 
     
     
         12 . The formliner of  claim 1 , wherein said layer consists of said foam material. 
     
     
         13 . The formliner of  claim 1 , wherein each raised portion comprises an arcuate shape. 
     
     
         14 . The formliner of  claim 1 , formed by a process comprising molding a flat sheet of foam material to form said raised portions. 
     
     
         15 . The formliner of  claim 14 , wherein said molding comprises using a mold having a shape defining object locations separated by raised portions. 
     
     
         16 . A formliner for casting objects into a cured wall, the formliner comprising:
 a contoured layer of foam material comprising a plurality of object locations separated by raised portions, said raised portions comprising row members and column members, said row members being nonparallel to said column members;   wherein a thickness of said foam material at a said object location is similar to a thickness of said foam material at a raised portion.   
     
     
         17 . The formliner of  claim 16 , wherein each raised portion defines airspace thereunder. 
     
     
         18 . The formliner of  claim 16 , wherein each raised portion comprises an arc formed in said foam material. 
     
     
         19 . The formliner of  claim 16 , wherein an outer surface of said formliner has no open cells. 
     
     
         20 . The formliner of  claim 16 , formed by a process comprising molding a flat sheet of foam material to form said contoured layer of foam material.