Patent Publication Number: US-2015069211-A1

Title: Thermoplastic liner for casting textures and objects into poured wall

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 12/047,128, filed Mar. 12, 2008, now U.S. Pat. No. 8,888,067, which claims priority to U.S. Application No. 60/906,435, filed Mar. 12, 2007, the entire content of which are hereby incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention in general relates to a re-usable liner that can be used for making textures into concrete, as well as a form liner for securing and sealing objects in a form so that when a wall is poured the objects remain fixed to the surface by being partially embedded when the form and the liner are withdrawn. 
     The construction industry in the last several decades has taken advantage of the cost and structural benefits of simulated brick or simulated stone walls over traditional masonry, and decorative designs. The method typically uses a form liner to create shapes and textures to create a decorative poured wall that can later be stained to look like traditional masonry and designs. A liner has also been used to place real brick, pavers or stones within the liner itself. The liner typically consists of a number of recessed areas separated by joints. The recessed areas are where the pavers, brick or stone are placed and the joints between the recessed areas holds the brick, pavers or stones from moving out of place. Typically a concrete slurry is then poured into the form and allowed to cure. The joints form a “grout line” around the pavers bricks or stones when concrete is poured into the form. Once the concrete is cured and the form and the liner is removed, a simulated wall is revealed with the stone, brick or pavers exposed on the surface and concrete exposed between the brick, stones or pavers which is the grout line. The goal is to make the poured wall look like real masonry. Architects criticize that using a liner to create textures and then stain makes the wall look fake, that embedding bricks or pavers creates a wall that does not look like natural masonry because the grout joints are all the same width, that bricks are too uniform in size and, in some applications, that the created joints are flat rather than semicircular as the joints of hand laid brick. 
     Over the years there have been a number of different types of form liners have been used, each with various drawbacks. All of these liners added to cost and labor, especially when forming inlayed brick into poured walls. 
     Solid urethane liners have been used for a number of years, but not for embedding objects in a poured wall when there is a full tooled joint. A full tooled joint is a joint that has a semicircular top and the sides of the joint and extends down to touch the bottom part of the brick that fits into the cavity. The full “tooled joint” or a semicircular joint, is the preferred architectural design because it is the standard masonry joint between the brick. The joint used with urethane liners is a flat joint, also called raked joint urethane liners. Such liners are expensive, labor intensive and the result is typically an unnatural looking wall. They are not used in the precast industry when used to embed objects into the surface of a wall with a natural full tooled joint; not only because of the expensive price per square foot but it is difficult to get urethanes soft enough to seal bricks and allow for variable brick sizes to fit into the cavity between the joints. 
     U.S. Pat. No. 5,900,180 is an attempt for an inexpensive way of producing flat joint or raked joint liners using foam. It is manufactured by die cutting or routing a foam sheet into a grid pattern with square grout joints and gluing it to a paper backing. The areas that are die cut, specifically each vertical edge of every grout joint is a problem because the concrete sticks to the exposed cells of the foam. When the form is removed, the liner breaks apart and the foam joints are stuck in the concrete panel between the brick pavers, resulting in costly cleaning due to manually scraping out the foam pieces from the grout lines of the simulated brick wall. The design disclosed in U.S. Pat. No. 5,900,180 does not allow for variable sized brick because it was designed so that the foam grid is glued to a flat backing that is not flexible, causing the foam grid to be fixed where the foam meets the backing. The recessed area where brick pavers seat require very tight tolerances in the brick pavers. If the bricks are too large, the foam material does not have give and pushes the brick upward out of the recessed area resulting in a misalignment. The expensive cost of grinding the brick, waxing the brick and manually scraping the foam out of the finished wall has made this liner an undesirable product to use. Furthermore, this reference with its flat and uniform grout joints segregates this liner to another type of architectural look, a liner that makes the wall look fabricated and not like real masonry. 
     Prior plastic liners such as the VersaLiner™ panel manufactured by Innovative Brick Systems, Inc. of Bloomfield, Colo. have been able to achieve a tooled joint but in doing so they have encountered many problems due to the rigid nature of the panel material and particularly the rigid nature of the semicircular joints between the recessed brick-receiving regions. These hard plastic joints define uniform brick-receiving regions in the liner panel which, in turn, require the use of brick pavers that are cut to very precise tolerances to fit close to the grout joint. The problem is that the cementous material seeps around the joint and to the brick face because there is no seal by the hard plastic against the brick edge. Further, the grout lines of plastic liners are not malleable and the grout joint cannot adjust to oversized brick pavers (i.e 1/16 inch or more out of specification in either the length or the height dimension) will not be seated correctly in the liner, partially seated on top of the grout joint and not able to seat in the cavity between the grout joints causing unacceptable visual defects in the finished wall. In order to ensure that the finished brick wall may be cleaned of any concrete material on the front face of the bricks, it is typically necessary to use specialized brick pavers that have had their faces coated with wax. Upon completion of the formed wall and the removal of the plastic liner panels, a hot water (high pressure) spray is applied to the face of the brick wall to remove the wax coating and any accumulated concrete material. This process is very labor intensive and costly to the contractor. It is worthy to note that the prewaxed brick pavers are expensive and even more expensive when the brick edges must be ground to fit the exact dimensions of the hard plastic liner, nearly doubling the cost of a standard brick paver. The plastic liners are not thermally stable, rising temperatures can cause the liner to expand and create even larger gaps between the brick pavers and the joints. Lower temperatures can cause the bricks to pop out of the brick cavity and seat on top of the grout joint. With all of the precision needed in the rigid plastic liner and the brick to make a brick faced wall, the result is a prefabricated wall that does not look hand laid. This liner is typically used one time and then discarded because it becomes destroyed when the concrete wall panel is removed from the form. 
     U.S. Publication 2006/0180731 A1 is another attempt to produce a tooled joint liner but has its own problems. U.S. Publication 2006/0180731 A1 is a laborious production method in which polystyrene extruded foam head joints are formed and cut separately from the polystyrene extruded foam bed joints. The individual joints are individually positioned in grooves on a conveyor belt track and the backing sheet is run simultaneously with the backing sheet under a heat roller which attaches the individual foam joints to the backing sheet. The recessed areas where the brick pavers are laid is sugar coated to act as a retarding agent for leaking concrete because the device does not completely seal the brick. The strips are glued directly to the backing and the recessed area has no flexibility because the bottom is glued to the paper. The reference states that when a brick is oversized, the contractor can detach the individual head joint and move it over and reattach the joint so that the brick will fit in. This creates a problem for the adjacent brick because the recessed cavity will be too short. The contractor must try to find a very small brick, cut the brick down or move the next joint over which continues to compound the problem. At some point in the row, brick pavers must be cut or ground which is very expensive and labor intensive. The reference tries to address the problem if a brick is too long by detaching the grout joint, but the reference liner fails to address the problem of a brick being too wide. This results in the probability that the contractor would purchase expensive precut brick and prewaxed brick to be safe from onsite grinding and extensive cleaning. Due to its material makeup, the reference liner can only be used once, the contractor must layout new liner for each pour which adds even more to the labor cost. Furthermore the grouts are made all with the exact same shape and the end results in prefabricated looking brick wall. 
     There remains a need for a form liner capable of being used with bricks and/or other inserts of various sizes without modification, capable of forming joints having the visual characteristics of a tooled mortar joint, capable of creating a wall section with realistic imperfections, and capable of being used multiple times. 
     All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety. 
     Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below. 
     A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims. 
     BRIEF SUMMARY OF THE INVENTION 
     In some embodiments, the invention provides an alternative material to be used as a form liner to form shapes and textures into a poured wall, and solves the above problems of a liner for partially embedding objects into a poured wall so that the face of the object is revealed in accordance with this invention. The liner can be placed within a form and holds objects in a desired pattern when the material is poured into the form and it covers the liner. In some embodiments, the liner is made of materials that are thermoformed into a continuous pattern of joints that define recessed areas in which stone, pavers, bricks or other objects can be placed in order to be cast into the poured wall. 
     In some embodiments, a re-useable liner can be used to imprint various shapes and textures as well as a plurality of joints which secure and seal objects within a form for a poured wall. The liner and the method of making the liner by thermoforming layers which comprises of a polyolefin foam sheet, a thermoplastic elastomer, and a polyolefin plastic. 
     In some embodiments, there is a closed cavity between the top layer and bottom layer of material that make up the grout joints of the liner. 
     In some embodiments there is an anti-expansion and contraction groove that is placed in the center of the recessed area and aligned with the vertical grout joints in the adjacent coursing to cushion any expansion or contraction due to temperature change. 
     In some embodiments the ability to attach one liner to another using adhesive on the butting ends to make a larger that would fit in a form. 
     In some embodiments is the use of a magnetic backing to be glued to the bottom layer to attach the liner when using metal forms. 
     In some embodiments is the design of the “tooled joint” or semicircular grout joint that is rounded at the top that extends below the plane of the recessed area where the objects are placed. 
     In some embodiments is variable width of the vertical grout joints all in one particular liner that make the simulated masonry look real. 
     In some embodiments is variable width of the horizontal grout joints all in one particular liner that make the simulated masonry look real. 
     These and other embodiments which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages and objectives obtained by its use, reference can be made to the drawings which form a further part hereof and the accompanying descriptive matter, in which there are illustrated and described various embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A detailed description of the invention is hereafter described with specific reference being made to the drawings. 
         FIG. 1  is a perspective view an embodiment of a liner. 
         FIG. 2  is a perspective view of an embodiment of the liner set inside of a horizontal form for casting concrete with bricks placed in the liner. 
         FIG. 3  depicts concrete poured into the form shown in  FIG. 2 . 
         FIG. 4  is a front elevation view of an embodiment of the liner. 
         FIG. 5  is a cutaway section of the front elevation view of an embodiment of the liner with a screw and washer. 
         FIG. 6  is a sectional view of  FIG. 5  showing the right elevation and an embodiment of a liner having three layers. The top and bottom layers are represented with hatching and dashed lines. 
         FIG. 7  is a sectional view of  FIG. 5  showing the bottom elevation and an embodiment of a liner having three layers. The top and bottom layers are represented with hatching and dashed lines. The figure includes a screw with washer and a magnetic sheet. 
         FIG. 8  is a sectional view of  FIG. 5  showing the bottom elevation and an embodiment of a liner having three layers. The top and bottom layers are represented with hatching and dashed lines. The figure shows an oversized brick above the liner not yet placed into the recessed area between the grout joints. 
         FIG. 9  is an enlarged sectional view of a portion of  FIG. 8  on the tooled joint, showing an embodiment of a liner having three layers. The top and bottom layers are represented with dashed lines showing they may not always be present. 
         FIG. 10  is a sectional view of  FIG. 5  showing the bottom elevation and an embodiment of a liner having three layers. The top and bottom layers are represented with hatching and dashed lines. The figure shows the oversized brick from  FIG. 8  placed into the recessed area between the grout joints. 
         FIG. 8   a . is a sectional view of  FIG. 5  showing the bottom elevation and an embodiment of a liner having three layers. The top and bottom layers are represented with hatching and dashed lines. The figure shows an oversized brick above the liner not yet placed into the recessed area between the grout joints wherein the grout joint structure has a closed cavity. 
         FIG. 9   a . is an enlarged sectional view of  FIG. 8   a . on the tooled joint, showing an embodiment having a closed cavity between the bottom layer and an adjacent layer. 
         FIG. 10   a . is a sectional view of  FIG. 5  showing the bottom elevation and an embodiment of the liner having three layers. The top and bottom layers are represented with hatching and dashed lines. The figure illustrates an oversized brick from  FIG. 8   a . placed into the recessed area between the grout joints where in the grout joint structure has a closed cavity. 
         FIG. 11  is a front elevational view of an embodiment of the liner and only showing the various dimensions in the grout joints. 
         FIG. 12  is a perspective view of an embodiment of the liner apparatus showing the thermal expansion/contraction mechanism. 
         FIG. 13  is perspective view of an embodiment of the liner placed upside down illustrating the thermal expansion/contraction mechanism. 
         FIG. 14  is a perspective view of an embodiment of the liner from the bottom right corner showing the adhesive and illustrating the adhesive&#39;s protective strip being peeled off. 
         FIG. 15  is a front elevational view of two liners being joined together after the adhesive&#39;s protective strip has been peeled off. 
         FIG. 16  is a perspective view of a liner that creates textures and shapes in the face of a concrete wall. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     While this invention may be embodied in many different forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. 
     For the purposes of this disclosure, like reference numerals in the Figures shall refer to like features unless otherwise indicated. 
       FIG. 1  illustrates an embodiment of the invention comprising a liner  74  designed to accommodate a set of bricks. The liner  74  of the present invention is used to position the bricks  22  into a desired pattern, for example as shown in  FIG. 2 . The liner  74  can be placed in a form  32  and a cementous material can be poured into the form so that the cementous material  44  covers all of the brick  22  and the joints  56 ,  58  of the liner  74  between the brick  22 , for example as shown in  FIG. 3 . When the cementous material  44  cures, the form  32  is removed and the liner  74  is removed from the wall. The bricks  22  have become embedded into the cementous material  44  with the face of the brick  22  exposed. The cementous material  44  between the brick  22  defines the grout lines, which comprise horizontal rows  56  and vertical columns  58 . Hereinafter, the rows  56  and columns  58  may be referred to as “joints.” 
       FIGS. 1 and 4  illustrate a liner  74  having a plurality of joints  56  and  58  arranged in a grid. In some embodiments, the liner  74  can be formed from thermoplastic materials. Specifically, the liner  74  can include a plurality of horizontal joints  56  extending parallel to one another, and a plurality of vertical joints  58  extending parallel to one another. The grid defines define a plurality of recessed areas  54  that can receive the brick  22 , and thus can comprise brick locations. An upper surface of each brick location/recessed area  54  can be oriented at a predetermined height. Each row  56  comprises a raised portion that is raised above the predetermined height of the recessed areas  54 . Similarly, each column  58  comprises a raised portion that is raised above the predetermined height of the recessed areas  54 . 
     The vertical columns  58  and horizontal rows  56  can have a sandblast texture  46  on the raised upper surface that simulates a tooled mortar joint in a hand lay-up mason wall. The vertical  58  and horizontal joints  56  can have different shapes and textures  46  as well, but the preferred shape in the industry, and one that looks like real masonry, is the semicircular or concave joint  12  as shown in  FIG. 1 . 
     In various embodiments, any suitable textures  46  (see  FIG. 16 ) and shapes for the “grout joints”  12  may be used in this invention. The grout joints  12  are arranged to give the ½ running bond pattern in  FIG. 4  which is the most common in the industry. This invention is not limited to this pattern, as it can be made into custom decorative brick  22  patterns as well as the other bond patterns such as ¼, ⅓ and full. 
     Referring to  FIGS. 6 and 7 , in some embodiments, a liner  74  can comprise multiple layers of material, including a first layer  16 , a second layer  18  and a reinforcing or third layer  20 . In some embodiments, the layers  16 ,  18 ,  20  can be thermoformed by methods including vacuum forming, compression molding, compression forming, pressure molding, pressure forming, injection molding, blow molding, embossing and heat molding. In some embodiments these layers  16 ,  18 ,  20  can be co extruded into a single sheet as then thermoformed into one liner  74 . In some embodiments, one or more layers can be extruded separately and then built-up before thermoforming into a single liner  74 , for example as shown in  FIG. 8   a .,  FIG. 9   a ., and  FIG. 10   a , which allows for a cavity  72  between various layers. 
     In some embodiments, the various layers can comprise polyolefin foam, thermoplastic elastomer and/or polyolefin plastic. Layers  16 ,  18 ,  20  shown in  FIGS. 6-10   a  will be described as follows: the top layer will be called layer I  16 , the middle layer will be called layer II  18  and the bottom layer will be called layer III  20 . 
     In some embodiments, layers I  16 , II  18  or III  20  can comprise solid polyolefin plastic. The solid polyolefin plastic is desirable for giving strength to the liner  74 . Polyolefin plastics have a high tear strength, a good flexural modulus and are very tough. They can withstand being used to cast concrete  44  several times without wearing out or chemically breaking down. Materials used in the casting process, such as concrete and other building materials, are less likely to stick or bond to polyolefin plastics than other materials, so the liner  74  can be cleaned easily between casting operations. The solid polyolefin plastic also does not expand or contract as much as other materials, such as polyolefin foams, so the solid plastic can be used in some embodiments to stop the lineal expansion and contraction of the foam layer, for example due to temperature change. 
     In some embodiments, a solid layer of plastic is 1/16 inch or less in thickness. In some embodiments a solid layer of plastic is 1/32 inch or less in thickness. In some embodiments, a solid layer of plastic is 0.020 inch or less in thickness. 
     In some embodiments, one or more layers  16 ,  18 ,  20  can consist of a polyolefin plastic, such as polypropylene (PP), and can further be filled with talc and extruded into sheets and then thermoformed. The advantage for using a talc filled polypropylene is: the coefficient of expansion is up to 4 times less than the coefficient of expansion of referenced liners, low cost, good chemical resistance, good resistance to stress cracking even when in contact with detergents or polar hydrocarbons which are in concrete release agents, very good fatigue resistance for multiple uses, retains mechanical properties at elevated temperatures such as high temperature steam curing for concrete  44 , mechanical properties are unaffected by submersion in water. 
     In some embodiments, one or more layers  16 ,  18 ,  20  can consist of a polyolefin such as polyethylene (PE), which has excellent chemical resistance, very good process ability and very low cost. 
     In some embodiments, one or more layers  16 ,  18 ,  20  can consist of a polyolefin such as Ethylene Vinyl Acetate, which is highly flexible even at low temperatures (−25 C), highly compatible with thermoplastic elastomers, has excellent tear resistance to withstand stripping out of concrete  44  from the form  32  and liner  74 , has excellent resistance to stress cracking for multiple re-uses and has a good UV and ozone resistance so it can be stored and used outside without deterioration. 
     In some embodiments, one or more layers I  16 , II  18 , or III  20  can comprise polyolefin foam. In some embodiments where the layer I  16  comprises polyolefin foam, the thermoforming process ensures that the foam cells are not exposed, and therefore ensures that the cementous material  44  does not stick to the liner  74  when the form  32  is taken away from the cured cementous material  44 . By thermoforming a polyolefin foam, it heats the foam and closes the cells at the surface, creating a protective shell that makes the liner  74  able to be used with concrete  44  in such that the liquid concrete  44  will cannot fill any foam cells because the foam cells are not exposed to the concrete  44 . 
     Previous attempts at using foam that was not thermoformed failed because the cut foam exposed the foam cells allowed the concrete  44  to fill the cells before curing, which created much labor in cleaning the concrete  44  because foam particles become stuck to the concrete  44 . Further, such a liner was a ‘single use’ liner because the foam would be destroyed in the process. 
     A thermoformed polyolefin foam that has no open cells will resist sticking to the concrete, and can be therefore used several times. Often, a thermoformed polyolefin foam can be used until the friction of the bricks  22  wears through the protective surface layer created in thermoforming process. In some embodiments the polyolefin foam is crosslinked. 
     Referring again to  FIG. 1 , in some embodiments, the liner  74  can be attached to another substrate  78  such as fiberglass, paper, cardboard, wood, plastic, etc., for example by bonding. The substrate  78  can act to structurally reinforce the liner  74 , bracing the liner  74  against dimensional changes such as expansion and contraction, for example due to temperature changes. 
     In some embodiments, use of a substrate  78  can form an air pocket or closed cavity  72  underneath the joints  56 ,  58 . A cavity  72  can increase the range of brick sizes that are suitable for use with the form liner  74 , as the joints  56 ,  58  more easily conform to oversized bricks. 
     Referring to  FIG. 10 , in some embodiments, a layer of polyolefin foam can also increase the range of brick sizes that are suitable for use with the form liner  74 . The foam can be used to cushion and seal an oversized brick  22 , as the foam is deformable similar to the aforementioned cavity  72 .  FIG. 10  illustrates how a brick  22  can fit into the recessed area  54  (see  FIG. 8 ) between the joints  56 ,  58  of the liner  74  when foam is used in either layer I  16  or layer II  18 .  FIG. 10  shows layer II  18  as a foam layer, and the foam compressing and conforming  48  in response to loading applied by the brick  22 . The flexible foam squeezes as the oversized brick  22  is placed into the recessed area  54  between the joints  56 ,  58 , and the liner  74  seals the around the brick  22 , which prevents cementous material  44  from leaking into the recessed area  54 . This can provide an economical advantage, as it is not necessary to wax or grind the brick  22 . 
     In some embodiments, one or more layers  16 ,  18 ,  20  can comprise or consist of a polyolefin foam called EVA foam or Ethylene Vinyl Acetate foam, which is highly flexible even at low temperatures (−25 C). It is highly compatible with thermoplastic elastomers and can be thermoformed along with solid polyethylene. EVA foam exhibits excellent tear resistance and resistance to stress cracking, which provides for multiple re-uses of the liner  74 . EVA foam further has good UV and ozone resistance, so it can be stored and used outside without deterioration. 
     In some embodiments, one or more layers  16 ,  18 ,  20  can comprise or consist of a polyolefin foam that is made from LDPE or low density polyethylene foam, which is also compatible with polyethylene solid plastics in the thermoforming process. LDPE foams have excellent chemical resistance, especially against release agents used to form concrete  44 . LDPE can be co extruded easily with PE and thermoplastic elastomers into a single sheet prior to thermoforming. Some embodiments can comprise or consist of polyolefin foam that is made of PP which is compatible to thermoforming with polypropylenes. 
     In some embodiments, a layer I  16 , II  18  or III  20  comprises a thermoplastic elastomer that is strong and flexible, allowing the liner  74  to be used many times. The thermoplastic elastomer is able to stretch and accommodate various sized bricks  22 , and also provides manufacturing benefits over other materials. A thermoplastic elastomer can be a thin sheet that is lighter weight and less expensive than possible with other materials. Another advantage is that the thermoplastic elastomer allows for forming a thin layer. The joints  56 ,  58  are able to bend and stretch, conforming to an oversized brick  22  while sealing the brick  22  simultaneously. 
     In some embodiments, a thermoplastic elastomer can comprise PP/EPDM (polypropylene/ethylene propylene diene monomer) which thermoforms very well and has advanced features, they are typically resistant to oils and UV light whereas other reference liners break down with form oil and sun exposure. PP/EPDM has great abrasion resistance to withstand the abrasion due to insertion of bricks  22  and subsequent removal of the liner  74 . 
     In some embodiments, a thermoplastic elastomer can comprise polyvinylchloride or TPE/PVC, which have excellent flexural fatigue resistance for multiple reuses, resistance to oils and chemicals to withstand a variety of inexpensive release agents used in the concrete industry. 
     In some embodiments, a thermoplastic elastomer can comprise one or more thermoplastic elastomers such as COPE (copolyester elastomer), EVA/VC (ethylene vinyl acetate/vinyl chloride), TPO (thermoplastic olefin), TPR (thermoplastic rubber) and PEBA (polyether block amide). 
     In some embodiments, layer II  18  comprises polyolefin foam and layer I  16  comprises polyolefin plastic. Further, in some embodiments, layer III  20  comprises thermoplastic elastomer. In some embodiments, layer II  18  comprises thermoplastic elastomer, layer I  16  comprises polyolefin plastic, and layer III  20  comprises polyolefin foam. In some embodiments, the two layers  16 ,  18  can be co-extruded and then thermoformed into the liner  74 . In some embodiments, each layer can be extruded individually, and the separate layers can be built-up and thermoformed. 
     The combination of foam and thermoplastic elastomer layers can be glued to a substrate  78  which may comprise of a paper/plastic ply, cardboard, plywood, plastic, metals, fiberglass, frp (fiberglass reinforced plastic) etc., which can limit any expansion and contraction of the layer I  16  and layer II  18 . This would form an air gap  72  between layer II  18  in the joint  56 ,  58  and the substrate  78  it is getting bonded to. Layer I  16  and II  18  can stretch, compress and flex to receive oversized bricks  22  while sealing the brick  22  completely around the bottom of the vertical edge of the brick  22 . The cavity  72  allows for layer I  16  and layer II  18  to flex even further. The thermoplastic elastomer typically has a high tear strength, abrasion resistant and is chemically resistant giving protection to polyolefin foam layer. With this combination, no expensive brick  22  grinding or waxing is needed saving in time and money. 
     In some embodiments, layer I  16  can be considered a release layer, for example being made from an elastomeric material. Desirably, the building materials used with the formliner will not adhere to the release layer. Thus, the layer I  16  can prolong the life of the formliner and allow the formliner to be used multiple times. In some embodiments, a release layer can comprise Styrenic Block Copolymers, Polyolefin Blends, Elastomeric Alloys or blends, Thermoplastic Polyurethanes, Thermoplastic Copolyester, Thermoplastic Polyamides and/or combinations thereof. In some embodiments, an elastomeric blend can comprise a thermoplastic elastomer and a polyolefin plastic, such as polypropylene and EPDM. A release layer is desirably thin, and will not interfere with flexion of the formliner. For example, a release layer can be less than 1/16″ or less, 1/32″ or less, etc. 
     In some embodiments, layer II  18  comprises a foam that is structurally suitable for use in the formliner. If too little foam is used, the formliner cannot flex to accommodate various sizes of bricks. If too much foam is used, the formliner becomes too bulky and bricks laid upon the formliner will move and be unstable if workers walk across the bricks. In some embodiments, a foam layer can be ⅜″ thick or less. In some embodiments, a foam layer can be ¼″ thick, ⅛″ thick or less. The thickness of the layer can be adjusted based upon the weight and elastic modulus of the foam to create desired properties in the formliner. For example, in testing, a foam layer of 0.014″ having a weight of 2-4 PCF (pounds per cubic foot) and an elastic modulus of 30 ksi exhibited suitable flexibility and support strength, while a similar layer of 0.014″ having a weight of 2-4 PCF (pounds per cubic foot) but an elastic modulus of 10 ksi did not have sufficient strength to adequately resist deformation under the weight of the concrete. 
     In some embodiments, layer III  20  comprises a reinforcement layer designed to provide reinforcing strength to the formliner. In some embodiments, a reinforcement layer is desirably less than 1/32″ thick. In some embodiments, a reinforcement layer comprises a material having a yield stress greater than that of layer II  18 . Desirably, the reinforcement layer will not interfere with flexion of the formliner. In some embodiments, a reinforcing layer can comprise a Polyolefin Plastic, ABS, PVC and/or combinations thereof. In some embodiments, a reinforcement layer comprises an elastic modulus in the range of 0-362 ksi. 
     In some embodiments, the liner  74  can comprise two layers of material. In some embodiments having two layers, I  16  and II  18 , no layer III  20  is needed, for example where layer II  18  includes enough strength that a reinforcing layer  20  is not necessary. In some embodiments, a two layer formliner comprises a layer of foam having a weight of 6 PCF (pounds per cubic foot) or more. In some embodiments having two layers, II  18  and III  20 , no layer I  16  is needed, for example where layer II  18  comprises a material that has adequate release characteristics. 
     In some embodiments, layer I  16  consists of a solid polyolefin plastic such as high density polyethylene (HDPE); layer II  18  consists of a polyolefin foam such as LDPE foam; and layer III  20  consists of a thermoplastic elastomer such as TPE/PVC. In some embodiments, these three layers  16 ,  18 ,  20  can be co-extruded together into one single sheet and then thermoformed into the liner  74 . 
     Referring to  FIGS. 8   a - 10   a,  in some embodiments, the layer I  16  and layer II  18  are co-extruded together and thermoformed separately from layer III  20 . The combination of layers I and II  16 ,  18  and layer III  20  can then be bonded together, in some instances while still hot, to create an cavity  72  in the joint  56 ,  58  between layer II  18  and layer III  20 . The cavity  72  allows for even further flex inward caused by extremely oversized bricks  22 . The high density polyethylene can provide stability and reinforcement to the foam layer. 
     High density polyethylene plastic is very durable and flexible so the liner  74  will withstand being stripped away from the concrete  44  several times. It has excellent chemical resistance. It also gives support to the ribs so that contractors can walk on it without destroying the liner  74 . 
     In some embodiments, layer II  18  is made from LDPE foam, which is very flexible and can compress very easily allowing the brick  22  to be oversized and still fit into the recessed area  54  between the joints  56 ,  58  as shown in  FIG. 7 ; without riding the joints  56 ,  58 ; binding the joints  56 ,  58 ; or without the need to remove individual joint  56 ,  58  pieces as may be necessary in prior art liners. The polyolefin foam is flexible enough to create a true seal against the brick  22  so the cementous material  44  poured against it will not seep past the seal and flow to the face of the brick  22 . 
     In some embodiments, layer III  20  comprises or consists of TPE/PVC which is a durable material that will endure abuse caused by cementous materials  44  and the rough bricks  22  within the liner  74 . The elastomer stretches and allows oversized brick  22  to squeeze into the foam creating a true seal. It also has great abrasion resistance and flexural fatigue resistance so that the liner  74  can be used several times. The TPE/PVC also protects the foam with its excellent toughness, tear strength and excellent weather ability. These advanced features allow for great money savings in grinding and waxing of the brick  22  and save much money and labor by being able to reuse the liner  74  over and over. Furthermore, the thermoplastic elastomer can be formed into textures  46  that facilitate a natural look to the grout between the brick  22  or stone  22  or pavers  22 . 
     In some embodiments, layer III  20  is planar in shape except for expansion/contraction grooves  64  optional air spaces  62  formed on the underside of the joints  56 ,  58 . In this embodiment, layer I  16  retains the profile as depicted in  FIGS. 8   a - 10   a  while layer III  20  is planar across the region spanning from an air space  62  to an expansion/contraction groove  64 . Layer III  20 , therefore, has indentations at air space  62  and expansion/contraction groove  64  but not between. As a result, portions of layer II  18  are enlarged to occupy the space between indented layer I  16  and layer III  20 . 
     Some embodiments can comprise or consist of a thermoplastic elastomer thermoformed with a solid polyolefin plastic to make a liner  74  for embedding objects  22  into a poured wall  44  or making textures  46  and shapes into a poured wall  44 . 
     In some embodiments, layer I  16  consists of the thermoplastic elastomer(s) and layer II  18  consists of a solid polyolefin plastic in the case of them being co-extruded together as shown in  FIG. 9 . In some embodiments, layer I  16  consists of a thermoplastic elastomer and layer III  20  consists of a solid polyolefin plastic as shown in  FIG. 9   a , where the sheets can be thermoformed separately creating a cavity  72  between layer II  18  and layer III  20 . 
     Any embodiment can include a cavity  72  between adjacent layers of material. The cavity  72  allows for the formliner to flex into the cavity  72  when an oversized brick  22  is place into the recessed area  54  between the joints  56 ,  58 . The cavity  72  combined with a flexible material layer allows a brick to snuggly fit into the recessed area  54  between the joints  56 ,  58  while sealing around the brick  22  eliminating any need for waxing or grinding of the brick  22 . 
     In some embodiments, a polyolefin plastic gives the thermoplastic elastomer more stability so it cannot deform or deflect when walked on or when concrete  44  if poured and also keeps it from expanding and contracting. 
     Some embodiments comprise PP/EPDM that can be thermoformed together with polypropylene wherein layer I  16  is PP/EPDM and layer II  18  is polypropylene, which in some embodiments can be talc filled, for example in the case of them being co extruded together as shown in  FIG. 9 . In some embodiments, layer I  16  consists of PP/EPDM and layer III  20  consists of talc filled polypropylene. 
     The process of thermoforming talc filled polypropylene and PP/EPDM separately and then bonding them together is called twin sheet vacuum forming. Talc filled polypropylene has a very low coefficient of expansion from 2.22-4.44 (10-5 F-1) it is also low cost and the talc gives the polypropylene more rigidity to support the PP/EPDM layer. With polypropylene and PP/EPDM&#39;s ability to retain excellent mechanical properties in elevated temperatures during steam curing of the concrete  44  with very good fatigue resistance, good resistance to standard inexpensive release agents in the concrete industry, this liner  74  able to withstand multiple reuses gives great value to the contractor. Furthermore the EPDM can have a durometer as low as 35 shore A which allows this elastomer to flex and stretch at the same time to allow oversized brick  44  to seal against the joints  56 ,  58  when seated into the recessed area  54  between the plurality of joints  56 ,  58 . With a true seal, an elimination of brick  22  grinding, brick waxing or any kind of retarder placed on the liner  74 , lowers the cost and labor to make a poured wall  44  that embeds brick  22  pavers on the surface. 
     Structurally, an advantage of the liner  74  is its ability to contract and expand and remain usable at a construction site over a wide range of temperatures, from below zero to over 100 degrees Fahrenheit. Additionally, the liner  74  can withstand temperature changes caused by the cementous material  44 , for example heat generated by the curing process can cause temperature changes of 40-60 degrees Fahrenheit. The expansion grooves  64 , described below, allow the formliner to adjust for temperature change and to accept oversize or non-standard sized bricks. 
     In some embodiments a liner  74  comprises a channel  10  or recess adjacent to the joints  56 ,  58  as shown in  FIG. 1  and  FIGS. 5-10   a.  The channel  10  is designed to follow each joint  56 ,  58  as shown in  FIG. 1 . The channel  10  is designed to allow the polyolefin foam and/or thermoplastic elastomer to flex, as shown in  FIGS. 10 and 10   a , because the base of the joint  56 ,  58  is not attached at the plane at which the object  22  is seated. Such channels  10  can run adjacent to any and all joints  56 ,  58 . 
     In some embodiments a liner  74  comprises a plurality of expansion/contraction grooves  64  as illustrated in  FIGS. 12 and 13 . An expansion groove  64  can comprise an undulation in the formliner (see also  FIG. 8 ). An upper surface of each expansion groove  64 , or the upper surface of the formliner material located above an expansion groove  64 , can be oriented at a height that is less than the predetermined height of the brick locations. 
     The grooves  64  can be formed on the underside of the liner  74  at any suitable location. In some embodiments, the grooves  64  are aligned under the columns  58 . In some embodiments, air spaces  62  can be formed at some locations under the columns  58 . It should be noted that due to the staggered brick pattern, a column  58  can define alternating raised portions and tray portions. The grooves  64  can be located under a tray portion, while the air spaces  62  can be located under the column  58  raised portions, for example as shown in  FIG. 13 . Thus, in some embodiments, a channel is formed under a column  58 , comprising alternating airspaces  62  and expansion/contraction grooves  64 . The cross-sectional area of the airspaces  62  can be different from the cross-sectional area of the expansion/contraction grooves  64 . In some embodiments, the cross sectional area of the airspaces  62  on the underside of a vertical joint  58  is greater than the cross sectional area of the corresponding airspace on the underside of the expansion/contraction grooves  64 . The underside of adjacent vertical joints  58  can be staggered, thus an airspace  62  of one vertical joint  58  can be horizontally aligned with expansion/contraction grooves  64  of adjacent vertical joints  58 . The grooves  64  solve a problem of horizontal expansion  68  and contraction  66  (see  FIG. 13 ), for example due to temperature change, as the airspaces  62  and grooves  64  can absorb the dimensional changes of the liner  74 . The airspaces  62  and grooves  64  form a continuous vertical channel. 
     In some embodiments a liner  74  comprises a fastener pocket  38 .  FIGS. 1 ,  5  and  7  illustrate the pockets areas  38  that are formed within the recessed area  54  where the objects  22  can be disposed. These pockets  38  are made for fasteners  34  to sit under the object  22  being cast into a poured wall  44 , for example to attach the liners  74  to forms.  FIG. 5  shows a top view of the liner  74  illustrating the areas where a nail or screw  34  and washer  36  can be placed in order to fasten it to a form system  32 . An upper surface of a fastener pocket  38  is recessed below the predetermined height of the brick location/recessed area  54 . Preferably, the upper surface of a fastener pocket  38  is low enough that an upper surface of a fastener  34  is oriented at a height that is below the predetermined height of the brick location/recessed area  54 . 
     Some embodiments comprise of joints  56 ,  68  in which a cavity  72  is formed between two layers  16 ,  18 , or  20  of materials the make up the joint  56 ,  58  in the liner  74  as depicted in  FIGS. 1 ,  8   a - 10   a  and  14 . This cavity  72  allows for the layer of thermoplastic elastomer to stretch, flex and compress into or collapsing the cavity  72  as oversized bricks  22  are placed into the recessed area  54  between the plurality of joints  56 ,  58 . 
     Referring to  FIG. 11 , in some embodiments a formliner can comprise varying grout widths  26 ,  28 ,  30  in the joints  56 ,  58 . The liner  74  provides for varying grout widths  26 ,  28 ,  30  while the liner is in its native pre-stressed state (i.e., before bricks have been placed in the liner  74 ). This can be accomplished by changing the dimensions of the joints  56 ,  58  in the form, for example changing width dimensions, degree of curvature, etc. A wall made using a liner  74  arranged to produce varying widths  26 ,  28 ,  30  in the joints  56 ,  58  can look more like real masonry. The cavity or the recessed area  54  where the object  22  sits can remain the same dimensions, but the grout widths  26 ,  28 ,  30  can have different dimensions relative to one another. For example,  FIG. 11  shows a three vertical joints  58  in one row of brick locations. One of the joints  58  can be the neutral dimension  28 , one can be a plus dimension  30  and the other can be a negative dimension  26 . Preferably, the overall dimension of each row of bricks in the formliner is equal—thus, width adjustment of grout joints can be selected to create equal overall dimensions. The same can be done for horizontal joints  56 . One joint can be slightly wider  30  than the other as long as there is a narrower joint  26  to cancel out the positive dimension  30 . 
     A slight variation in the width of grout joints  56 ,  58  creates a more natural looking wall that resembles hand-laid masonry. 
     In some embodiments, two separate liners  74  can be made for special cuts vertically and a liner  74  can be made for special cuts horizontally in order to facilitate custom sizes for a casting bed or form  32 . The liner  74  for vertical cuts can have the same random width  26 ,  28 ,  30  along the horizontal row  56  as the original liner  74  with varying grout joint widths  26 ,  28 ,  30  along the horizontal row  56  but each vertical joint  58  would have the same width so that the liner  74  can be cut in a straight line and follow the vertical joints  58 . When special cuts need to be made horizontally, the vertical joints  58  can be made to have random widths  26 ,  28 ,  30  and the horizontal joints can all be made with the same neutral width  28  in order to facilitate exact fitting into the form  32 . The result is a natural looking brick wall with random width grout joints  26 ,  28 ,  30  as a mason would create when hand laying brick, in contrast to previous attempts at manufactured brick walls having uniform grout joints. 
     In some embodiments, inventive liners  74  provide a solution for matching adjacent liners  74  when casting a wall using multiple liners  74 . A liner  74  can comprise an adhesive  40  on one or more sides of the liner  74 , as illustrated in  FIG. 14 . The liner  74  can be made into a larger liner  74  by matching two liners  74  side by side or top to bottom with one side having no full grouts  52  vertically and the matching side having a full grout  50  vertically and the top have no full grout  52  horizontally while the matching bottom side has a full grout  50  horizontally with the possibility of continuing to add on more liners  74  until a desired size is reached. The sides would be coated with an adhesive  40  with a protective layer  42  that would be pealed away exposing the adhesive  74 . As shown in  FIG. 15 , the ends of adjacent liners  74  are butt together  70  with the joints  56 ,  58  properly aligned. The film that protects the adhesive  42  can be left on the sides of the liner  74  until it is ready to be placed into the form  32  and it can be used to attach to the sides of the form  32  in order to stop the any leakage of cement slurry  44  from migrating under the liner  74 . By allowing a large liner  74  to be constructed prior to shipment to the contractor saves the contractor in labor and therefore reducing his time. 
     In some embodiments, a liner  74  can comprise a magnetic sheet  24  that is useful for attaching the liner  74  to building materials such as metallic flanges. In some embodiments, the aforementioned substrate  78  can comprise a magnetic material. The magnetic sheet  24  can be attached to the liner  74  using any suitable method, such as using an adhesive. The major advantage of this embodiment is that the end user does not have to drill holes in the steel form, which is very time consuming and very expensive to repair afterwards. 
     In some embodiments, the invention is directed to methods of making liners  74  as disclosed herein. 
     In some embodiments, for example a liner  74  comprising a single material, the material can be extruded to form a precursor sheet, and the precursor sheet can be thermoformed in a mold, for example under heat and pressure, to form the liner  74 . In some embodiment, the precursor sheet can be preheated to a predetermined temperature while disposed in the mold, and after reaching the predetermined temperature, pressure can be applied. The mold can be used to impart the shapes and structural features of the liner  74  as disclosed herein. 
     In some embodiment, for example a liner  74  comprising multiple layers of material, the multiple layers can be co-extruded to form a sheet, and the sheet can be thermoformed in a mold, for example under heat and pressure, to form the liner  74 . When more than two layers are desired, in some embodiments, all of the layers can be co-extruded simultaneously. In some embodiments, for example when a co-extrusion machine is only capable of co-extruding two materials simultaneously, a first layer and a second layer can be co-extruded to form an intermediate sheet, and the intermediate sheet can be fed through the machine while co-extruding one or more layers to form the precursor sheet, which can then be thermoformed in a mold to form the liner  74 . 
     In some embodiments, a liner  74  can be thermoformed as described above, and then attached to a substrate, for example to provide structural reinforcement to the liner  74 . 
     In some embodiments, for example a liner  74  comprising multiple layers of material, the layers can be thermoformed individually, and the two layers can be brought together under conditions that cause the layers to adhere to one another. In some embodiments, at least one layer can be at a temperature above its glass transition temperature when the layers are placed in contact. In some embodiments, both layers can be above their individual glass transition temperatures. In some embodiments, the layers can be secured using an adhesive, such as glue, pressure sensitive adhesive, adhesive tape, etc. 
     In some embodiments, for example when a cavity  72  is disposed between individual layers  16 ,  18 ,  20  of a liner  74 , a first portion and a second portion can each be formed as described above, and the two portions attached to one another. For example, with reference to  FIG. 9   a , a first portion  92  can comprise a first layer  16  and a second layer  18 . The second portion  94  can comprise a third layer  20 . The first portion  92  can be formed as described above, as well as the second portion  94 , and the two portions  92 ,  94  attached to one another. In some embodiments, the material used to form the first layer  16  and the second layer  18  can be co-extruded to form a first precursor sheet, and the material used to form the third layer  20  can be extruded to form a second precursor sheet. The first and second precursor sheets can each be thermoformed in separate molds, for example under heat and pressure, thereby imparting the individual shapes to the first portion  92  and the second portion  94 . The two portions  92 ,  94  are then attached to one another. In some embodiments, the two portions  92 ,  94  can be placed in contact under adherent conditions, for example prior to cooling after the molding process, wherein the materials of the portions  92 ,  94  can adhere to one another. 
     Further, some embodiments comprise a reinforcing layer III  20 . In some embodiments the reinforcing layer can be comprised of a polyolefin plastic material such as EVA, PE, PP; ABS (acrylonitrile butadiene styrene), PS (polystyrene), PVC, ASA/PVC (acetylsalicylic acid/polyvinyl chloride), PC (polycarbonate), CA (cellulose acetate), CP (cellulose Propionate), PA (polyamide), PAR (polyarylate), CAB (cellulose acetate butyrate), or paper. In some embodiments, layer II  18  comprises a crosslinked closed cell thermoplastic polyolefin foam material such as LDPE or EVA. Finally, in some embodiments, a first layer  16  comprises a thermoplastic elsastomer (TPE) or thermoplastic rubber (TPR) materials, such as: styrenic block copolymers, polyolefin blends, elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyester, thermoplastic polyamides. Specifically, the material can comprise an elastomeric alloy such as PP/EPDM. 
     The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this field of art. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims. 
     Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim  1  should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below. 
     This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.