Liner system for forming concrete panels

Abstract

A form for creating a pattern in uncured concrete during a casting process includes a support frame and a perforated reinforcing structure coupled adjacent to at least a portion of the support frame. The perforated reinforcing structure includes a plurality of apertures defined therein. A pliable liner is disposed at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure adjacent the support structure. The pliable liner has a patterned surface formed thereon for creating a corresponding pattern in uncured concrete poured adjacent the form.

1 . A form for creating a pattern in uncured concrete during a casting process, comprising: 
 a support frame;    a perforated reinforcing structure, coupled adjacent to at least a portion of the support frame and having a plurality of apertures defined therein; and    a pliable liner, disposed at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure adjacent the support structure, the pliable liner having a patterned surface formed thereon for creating a corresponding pattern in uncured concrete poured adjacent the form.    
   
   
       2 . The form of  claim 1 , wherein the support frame includes a plurality of elongate, tubular members.  
   
   
       3 . The form of  claim 1 , wherein the reinforcing structure is formed of a substantially planar sheet.  
   
   
       4 . The form of  claim 1 , wherein the pliable material further includes a compliant polymer.  
   
   
       5 . The form of  claim 1 , wherein the pliable material further includes polyurethane.  
   
   
       6 . The form of  claim 1 , wherein the perforated reinforcing structure further includes expanded metal.  
   
   
       7 . The form of  claim 1 , wherein the perforated reinforcing structure further includes a material selected from the group consisting of: perforated metal, woven wire sheets and welded mesh sheets.  
   
   
       8 . A form system for creating a pattern in uncured concrete during a concrete casting process, comprising: 
 a base;    a pair of opposing end wall forms, extending upward from the base and defining end wall surfaces of a vertical mold cavity for uncured concrete; and    a pair of opposing side wall forms, extending upward from the base and defining side wall surfaces of the vertical mold cavity, the opposing side wall forms each including at least: 
 a perforated reinforcing structure having a plurality of apertures defined therein; and  
 a pliable liner, disposed at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure, the pliable liner having a patterned surface formed thereon for creating a corresponding pattern in uncured concrete poured adjacent the form.  
   
   
   
       9 . The system of  claim 8 , further comprising a lower support gasket disposable over the base to at least partially define a bottom surface of the vertical mold cavity.  
   
   
       10 . The system of  claim 8 , wherein the end walls each include: 
 a perforated reinforcing structure having a plurality of apertures defined therein; and    a pliable liner, disposed at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure.    
   
   
       11 . The system of  claim 8 , wherein the side walls and end walls are operably positionable to form a tetragonal mold cavity.  
   
   
       12 . The system of  claim 8 , further comprising securing structure associated with the end wall forms and the side wall forms, and being configured to retain the end wall forms and the side wall forms in a secure configuration to receive concrete in an uncured state within the mold cavity.  
   
   
       13 . The system of  claim 12 , further comprising a plurality of side wall forms, end wall forms and lower gaskets disposed within the securing structure, to define a plurality of vertical mold cavities to enable simultaneous vertical casting of multiple concrete panels.  
   
   
       14 . The system of  claim 8 , wherein the perforated reinforcing structure further includes a material selected from the group consisting of: expanded metal, perforated metal, woven wire sheets and welded mesh sheets.  
   
   
       15 . A method for making a form for vertically molding concrete, comprising the step of: 
 a) obtaining a support frame;    b) coupling a perforated reinforcing structure to at least a portion of the support frame, the reinforcing structure having a plurality of apertures disposed therein; and    c) disposing a pliable liner at least partially within the plurality of apertures and at least partially about the perforated reinforcing structure adjacent the support frame.    
   
   
       16 . The method of  claim 15 , comprising the further step of: 
 curing the pliable liner to form a mold surface for retaining uncured concrete.    
   
   
       17 . The method of  claim 15 , wherein the support frame includes a plurality of elongate, tubular members.  
   
   
       18 . The method of  claim 15 , wherein the step of coupling the perforated reinforcing structure further comprises coupling a substantially planar sheet of expanded metal to at least a portion of the support frame.  
   
   
       19 . The method of  claim 15 , wherein the pliable liner includes a compliant polymer.  
   
   
       20 . The method of  claim 15 , wherein the perforated reinforcing structure further includes a material selected from the group consisting of: perforated metal, woven wire sheets and welded mesh sheets.