Patent Publication Number: US-2011073747-A1

Title: Brick formliner apparatus and system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. patent application Ser. No. 11/099,347 filed Apr. 5, 2005, claiming priority to U.S. Provisional Patent Application No. 60/650,934, filed Feb. 8, 2005, entitled “FORMLINER APPARATUS,” both of which are hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to formliners and, more particularly, to a brick formliner apparatus that uses substantially randomly positioned brick depths. 
     BACKGROUND OF THE INVENTION 
     Architectural designs for various types of construction, including buildings and bridges, call for the use of brick in the walls of buildings. Although of little structural importance in modern construction projects, brick walls continue to be used for decorative architectural purposes. However, making walls entirely of brick and mortar has become relatively expensive in recent years in comparison to poured concrete. One development that has reduced the cost of brick walls has been the use of decorative thin bricks, which are cast into concrete wall panels. Such decorative bricks are significantly thinner than normal bricks and therefore are significantly less expensive than normal bricks per square foot of wall coverage. 
     However, since decorative bricks cannot be made into a regular brick wall, a new type of technology was required. In order to cast the decorative bricks into the concrete walls, polymer brick formliners were developed, which have a plurality of brick-receiving recesses. The brick-receiving recesses are designed to hold the decorative bricks in place during the casting of concrete walls. The brick-receiving recesses are formed into the formliners in regular brick patterns, with each recess having the same depth distance, so as to create a clean and organized brick appearance in the final panel product. Such formliners are first placed on a surface capable of supporting the weight of the formliners, decorative bricks, and poured concrete. Decorative bricks are then placed into the formliners and concrete is cast on top of the decorative bricks and formliners. 
     Unfortunately, the clean and organized appearance of the final brick-lined concrete panel has resulted in an unforeseen aesthetic problem. The use of such formliners in the manufacture of buildings has resulted in a very consistent appearance in such look for such prefabricated wall sections. One purpose that drove the development of brick formliners was the creation of a wall that had the appearance of hand-laid brick, without the extra cost associated with hand-laid brick. Normally, the use of manual labor in the laying of brick walls results in a brick wall in which some bricks extend further out of the wall than other bricks, as a result of normal human imprecision in construction. However, the regularity and precision of the thin brick placement, which is the result of the use of such polymer brick formliners, has resulted in the mass production of brick lined concrete panels that appear as though they have been manufactured by a machine rather than built up by hand. 
     The general construction and function of formliner apparatuses are well known in the art. Such formliners include the formliner described in U.S. Pat. No. 3,602,476 to Iragorri, assigned to San-Vel Concrete Corporation, which is incorporated by reference herein in its entirety, the formliner described in U.S. Pat. No. 6,164,037 to Passeno, which is incorporated by reference herein in its entirety, and the formliner described in U.S. Pat. No. 6,041,567 to Passeno, which is incorporated by reference herein in its entirety. 
     Formliners are often used modularly, such that several formliners must be lined up end to end or top to bottom in order to hold sufficient numbers of bricks or other elements for a wall. The joints between such formliners are often simply planar joints butted next to one another. When cementitious material is applied to the surface of such joints, the cementitious material may flow through the planar joints, resulting in extra time and labor to clean up the cementitious material that flowed through the planar joints. 
     Formliners are often used with plywood backing, which is either cured into or glued into the main portion of the formliner. Such plywood is provided to add additional structural strength and stability to the formliner. However, such plywood may become dislodged during the use of the formliner, particularly if the formliner is used numerous times. 
     What is needed is a new type of formliner that can be used to manufacture a brick wall that has the appearance that it was built by hand, rather than manufactured with a brick formliner. What is also needed is a formliner that prevents the flow of cementitious material. What is also needed is a formliner that provides better structural stability. The present invention provides this advantage as well as other related advantages. 
     SUMMARY OF THE INVENTION 
     The present invention is a formliner apparatus comprising a plurality of substantially planar layers. The formliner further comprises a plurality of ribs extending in a direction away from the substantially planar layers and defining a plurality of recesses within the formliner in conjunction with the substantially planar layers, each of the plurality of ribs extending to a preselected rib plane. The present invention further comprises at least one resilient ridge on each rib defining each recess, each at least one resilient ridge extending into an adjacent recess, wherein each substantially planar layer is substantially parallel with the rib plane and located a preselected variance depth distance from the rib plane, each variance depth distance for at least some of the substantially planar layers being preselected from a preselected variance depth distance range, wherein each preselected variance depth distance is not equal to every other variance depth distance. 
     The present invention is also a formliner comprising a plurality of substantially planar layers. The present invention further comprises a plurality of ribs extending in a direction away from the substantially planar layers and defining a plurality of recesses within the formliner in conjunction with the substantially planar layers, each of the plurality of ribs extending to a preselected rib plane. The formliner further comprises at least one resilient ridge on each rib defining each recess, each at least one resilient ridge extending into an adjacent recess; wherein at least one pad is positioned in at least two of the recesses, each at least one pads comprising a pad surface, each pad surface being positioned a preselected pad variance distance from each substantially planar surface in the at least one of the recesses, each pad surface being located a preselected pad depth distance from each respective at least substantially planar surface, wherein each preselected pad variance depth distance is not equal to every other pad variance depth distance. 
     The present invention is also a formliner comprising a plurality of substantially planar layers. The formliner further comprises a plurality of ribs extending in a direction away from the substantially planar layers and defining a plurality of recesses within the formliner in conjunction with the at least substantially planar layers, each of the plurality of ribs extending to a preselected rib plane, at least one exterior rib being positioned at an exterior edge of a formliner, the at least one exterior rib having an exterior side and an interior side, the interior side facing one of the recesses, the exterior side facing away from the recesses. The formliner further comprises at least one internal resilient ridge on each rib defining each recess, each at least one internal resilient ridge extending into an adjacent recess. The formliner further comprises at least one external resilient ridge on the exterior side of the at least one exterior rib, the at least one external resilient ridge facing away from the recesses. 
     The present invention is also a formliner comprising a main portion, the main portion comprising a plurality of substantially planar layers, a plurality of ribs extending in a direction away from the substantially planar layers and defining a plurality of recesses within the formliner in conjunction with the substantially planar layers, each of the plurality of ribs extending to a preselected rib plane, and at least one resilient ridge on each rib defining each recess, each at least one resilient ridge extending into an adjacent recess. The formliner also comprises a backing portion, the backing portion comprising a body, wherein at least one notch is formed in a substantial portion of the body, wherein an extension of the main portion extends into the at least one notch. 
     An advantage of the present invention is that the depth distances of at least substantially planar recess surfaces are varied, providing a brick veneer wall manufactured with the formliner of the present invention with the appearance of hand laid brick. 
     Another advantage of the present invention is that a brick veneer wall manufactured with the formliner of the present invention has a substantially seamless appearance of cementitious material after application without subsequent clean-up operation. 
     Another advantage of the present invention is that a backing is more firmly attached to a main section of a formliner, reducing the chances that the backing will be dislodged during use. 
     Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an embodiment of the formliner of the present invention with substantially random and at least substantially planar recess surface depth distances. 
         FIG. 2  is a cross-sectional view of the formliner of  FIG. 1  taken along line  2 - 2 . 
         FIG. 3  is an alternate cross-sectional view of the formliner of the present invention taken along line  2 - 2 . 
         FIG. 4  is a cross-sectional view of the formliner of  FIG. 1  with bricks disposed in the formliner recess taken along line  4 - 4 . 
         FIG. 5  is a perspective view of another embodiment of the formliner of the present invention with substantially random and at least substantially planar recess surface depth distances and pads. 
         FIG. 6  is a cross-sectional view of the formliner of  FIG. 5  taken along line  6 - 6 . 
         FIG. 7  is a cross-sectional view of the formliner of  FIG. 5  with bricks disposed in the formliner recesses taken along line  7 - 7 . 
         FIG. 8  is a perspective view of yet another embodiment of the formliner of the present invention with at least substantially planar recess surfaces with substantially random pad thicknesses. 
         FIG. 9  is a cross-section view of the formliner of  FIG. 8  taken along line  9 - 9 . 
         FIG. 10  is a cross-sectional view of the formliner of  FIG. 8  with bricks disposed in the formliner recesses taken along line  10 - 10 . 
         FIG. 11  is a perspective view of another embodiment of the formliners of the present invention showing two formliners at prior to forming a transverse joint. 
         FIG. 12  is a perspective view of the formliners of  FIG. 11  after forming the transverse joint. 
         FIG. 13  is a perspective view of an embodiment of the formliners of the present invention showing two formliners prior to forming a lateral joint. 
         FIG. 14  is a perspective view of the formliners of  FIG. 13  after forming the lateral joint. 
         FIG. 15  is a fragmentary view in perspective showing an embodiment of the formliner of the present invention. 
         FIG. 16  is cross sectional view of the formliner of  FIG. 15  taken along the line  16 - 16 . 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention is a formliner apparatus, one embodiment of which is shown in  FIG. 1 . A brick formliner  100  is formed with a series of recesses  105 , which are separated by and defined by lateral ribs  110  and interconnecting transverse ribs  115 . The recesses  105  are shown in the figures in a brick running bond configuration, the configuration in which bricks are conventionally applied to walls. Such running bond configuration is only used to illustrate the features of the present invention and is not intended to limit the scope of the invention. Any other formliner configuration known in the art may also be used with the present invention, such as, for example flemish bond, basket weave, herringbone, etc. At the base of each recess  105  is an at least substantially planar recess surface  120 . The lateral ribs  110  and transverse ribs  115  extend from the at least substantially planar recess surfaces  120  to a rib plane  125  (shown in  FIG. 2 ). While the present invention is described using rectangular thin bricks  140 , it should be understood that the present invention works with any shape or size of brick or other element to be assembled into a wall or other construction element. 
     The formliner  100  is preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliner comprises cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprises cured sulfide RTV liquid rubber made from two liquid precursors. The formliner  100  is molded and cured as known in the art. 
     The formliner embodiments described herein may have any functional dimensions as known in the art for formliners. While  FIGS. 1-16  are not drawn to exact scale, these figures show the concepts set forth herein. For example, brick formliner  100  may be about 8 feet wide by 4 feet long by ⅜ inch deep. 
     Referring to  FIGS. 1-4 , ach of the lateral ribs  110  is provided with at least one resilient protrusion or ridge  130 , on every side of the lateral ribs facing a recess  105 . The at least one ridge  130  extends from the lateral ribs  110  into the recesses  105 . In addition, each of the transverse ribs  115  is provided with at least one resilient protrusion or ridge  135  on every side of the transverse ribs  115  facing a recess  105 , which also extends from the lateral ribs  110  into the recesses  105 . As known in the art, and as shown in  FIG. 4 , the at least one ridge  130 ,  135  engage and seal an adjacent surface of a brick  140  or other similar construction element, such as stone, tiles, stone slabs or other similar block elements, to prevent cementitious material  145 , shown in phantom in  FIG. 4 , from flowing into the interior of the recess  105  and contacting the front faces  150  of the bricks  140  (or other element). Each brick  140  is snugly and sealingly received in each recess  105 . Preferably, but optionally, the structure and number of the at least one lateral ridge  130  is substantially identical to the structure and number of the at least one transverse ridge  135 . It is preferred that more than one lateral ridge  130  be present on each lateral rib  110  for each recess  105  and more than one transverse ridge  135  be present on each transverse rib  115  for each recess  105 . For all embodiments set forth herein, in a preferred embodiment, the number of lateral ridges  130  for each lateral rib  110  for each recess  105  is in the range of from 1 to about 6 and the number of transverse ridges  135  for each transverse rib  115  for each recess  105  is in the range of from 1 to about 6. In a more preferred embodiment, the number of lateral ridges  130  for each lateral rib  110  for each recess  105  is in the range of from 1 to about 4 and the number of transverse ridges  135  for each transverse rib  115  for each recess  105  is in the range of 1 to about 4. 
     However, optionally, as shown in the alternate cross-section in  FIG. 3 , which is similar to the cross-section of  FIG. 2 , only one simple angular lateral ridge  130  extending from each lateral rib  110  and one simple angular transverse ridge  135  extending from each transverse rib  115  may be used for each recess  105 . In such a simple angle configuration, the portion of the lateral ridge  130  which extends furthest into the recess  105 , is located at the rib plane  125  and the portion of the lateral ridge  130 , which extends the least into the recess  105 , is located at the at least substantially planar recess surface  120 . 
     As shown in  FIGS. 1-4 , each at least substantially planar layer recess surface  120  is preferably disposed at a substantially randomly preselected variance depth distance from the rib plane  125 , such that every substantially randomly preselected variance depth distance is not identical to every other substantially randomly preselected variance depth distance. Each substantially random preselection described herein may be substantially randomly preselected by any means known in the art, for example, but not limited to a programmed random number generator on a computer. The substantially randomly preselected variance depth distance for each at least substantially planar recess surface  120  is substantially randomly preselected from a preselected variance depth distance range. The upper and lower limits of the preselected variance depth distance range are dependent upon the thickness of the brick  140  (or other element). The smallest value of the variance depth distance range cannot be too small or the brick  140  (or other construction element) will not be effectively sealed into the recess  105  by the at least one lateral resilient ridge  130  and the at least one transverse resilient ridge  135 , which can result in cementitious material adhering to the front face  150  of the brick  140 . The largest value of the variance depth distance range cannot be too large or the brick (or other construction element) will not extend far enough out beyond the rib plane  125  of the formliner  100  to effectively adhere into the cementitious material  145 . For example, if thin brick  140  is selected for use with a particular formliner  100 , and the thin brick  140  has profile outline dimensions of about 7½ inch long by about 3½ inch wide by about ½ inch thick, the variance depth distance range would be in the range of about ⅛ inch to about ¼ inch to achieve proper functioning of the formliner  100 . 
     In a preferred embodiment, each variance depth distance is substantially randomly preselected from a preselected set of variance depth distances, the set of variance depth distances comprising a preselected number of discrete preselected variance depth distances. In a preferred embodiment, the number of variance depth distances in the set is in the range of from 2 to about 5. In a more preferred embodiment, the number of variance depth distances in the set is 4. Each variance depth distance is substantially randomly preselected such that every substantially randomly preselected variance depth distance from the set is not identical to every other substantially randomly preselected variance depth distance from the set. One exemplary embodiment is shown in  FIG. 2  and  FIG. 3 , where the variance depth distance set includes four discrete variance depth distances, represented as α, β, Δ, and λ. In the embodiments shown in  FIGS. 1-4 , the largest depth distance is Δ, the next largest depth distance is β, the next largest depth distance is λ, and the shortest depth distance is α. For the use with thin brick  140  having dimensions of about 7½ inches long by about 3½ inch wide by about ½ inch thick, exemplary values for α, β, Δ, and λ are about ⅛ inch, about 11/32 inch, about 9/32 inch, and about 9/16, inch respectively as such symbols are used herein. 
     A first recess  155  has a variance depth distance of α, such that an at least substantially planar recess surface  175  is a depth distance of a from the rib plane  125 . A second recess  160  has a variance depth distance of β, such that an at least substantially planar recess surface  180  is a depth distance of β from the rib plane  125 . A third recess  165  has a variance depth distance of Δ, such that an at least substantially planar recess surface  185  is a depth distance of Δ from the rib plane  125 . A fourth recess  170  has a variance depth distance of λ, such that an at least substantially planar recess surface  175  is a depth distance of λfrom the rib plane  125 . Bricks  140  installed into the formliner  100  are shown in cross-section in  FIG. 4 . As in  FIG. 2 ,  FIG. 4  shows four separate recesses with bricks  140 , each recess again having a variance depth distance, one each of α, β, Δ, and λ. Cementitious material  145  is shown in phantom. A first brick  195  is shown positioned against at least substantially planar recess surface  175 , which is a depth distance α from the rib plane  125 . A second brick  200  is shown positioned against at least substantially planar recess surface  180 , which is a depth distance β from the rib plane  125 . A third brick  205  is shown positioned against at least substantially planar recess surface  185 , which is a depth distance Δ from the rib plane  125 . The fourth brick  210  is shown positioned against at least substantially planar recess surface  210 , which is a depth distance λ from the rib plane  125 . 
     During normal construction, after the bricks  140 ,  195 ,  200 ,  205 ,  210  are installed in the formliner, cementitious material  145  is poured into a structure, or form as known in the art, against the formliner  100  and bricks  140 ,  195 ,  200 ,  205 ,  210  to create a wall or other structure with the appearance of a hand laid brick wall (or other structure). As the cementitious material  145  cures, the bricks  140 ,  195 ,  200 ,  205 ,  210  are sealed within against the cementitious material. Once the cementitious material has sufficiently cured to retain the bricks  140 ,  195 ,  200 ,  205 ,  210 , the formliner  100  is removed from the cementitious material  145  and the bricks  140 ,  195 ,  200 ,  205 ,  210  leaving the bricks  140 ,  195 ,  200 ,  205 ,  210  set within the cementitious material  145 . 
     As is evident from the cementitious material in phantom  145 , once the formliner  100  is removed, the brick  205  that was positioned against the deepest at least substantially planar recess surface  185  extends the furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  200  that was positioned against the next deepest at least substantially planar recess surface  180  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  210  that was positioned against the next deepest at least substantially planar recess surface  190  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  195  that was positioned against the shallowest at least substantially planar recess surface  175  extends the least out from the cementitious material  145  as measured from rib plane  125 . Such variance in the extensions of the bricks  140 ,  195 ,  200 ,  205 ,  210  out from the cementitious material  145  results in a wall (or other construction element) with the appearance of a hand-laid brick wall rather than the appearance of a brick veneer wall that was manufactured with a conventional formliner  100 . 
     In another alternate embodiment of the present invention, each of the variance depth distances for each at least substantially planar recess surface is substantially randomly preselected from a set of variance depth distances, the set of variance depth distances comprising a preselected number of discrete preselected variance depth distances. In a preferred embodiment, the number of variance depth distances in the set is in the range of from 2 to about 5. In a more preferred embodiment, the number of variance depth distances in the set is 4. The preselected variance depth distances for each at least substantially planar recess surfaces are substantially randomly preselected from the set of variance depth distances such that each discrete variance depth distance in the set of variance depth distances is preselected for a substantially similar number of at least substantially planar recess surfaces as every other discrete variance depth distance. 
     In another alternate embodiment of the present invention, each of the variance depth distances for each at least substantially planar recess surface is substantially randomly preselected from a set of variance depth distances, the set of variance depth distances comprising a preselected number of discrete preselected variance depth distances. In a preferred embodiment, the number of variance depth distances in the set is in the range of from 2 to about 5. In a more preferred embodiment, the number of variance depth distances in the set is 4. The preselected variance depth distance for each at least substantially planar recess surface are substantially randomly preselected from the set of variance such that each discrete variance depth distance is used for at least one of the at least substantially planar recess surfaces. 
     In another alternate embodiment of the present invention, each variance depth distance for each at least substantially planar recess surfaces is non-randomly preselected from a preselected variance depth distance range so as to create the appearance of hand laid brick in the wall or other structure, such that each variance depth distance for each at least substantially planar recess surface is not identical to every other variance depth distance. In another alternate embodiment, each variance depth distance for each at least substantially planar recess surface is non-randomly preselected from a set of discrete preselected variance depth distances ranges so as to create the appearance of hand-laid brick in the wall or other structure, such that each discrete variance depth distance is used for at least one of the at least substantially planar recess surfaces. In a preferred embodiment, the number of variance depth distances in the set is in the range of from 2 to about 5. In a more preferred embodiment, the number of variance depth distances in the set is 4. 
     In an alternate embodiment of the present invention, as shown in  FIGS. 5-7 , a formliner  215  is shown with recesses  105 , lateral ribs  110 , transverse ribs  115 , at least substantially planar recess surfaces  120 , a rib plane  125 , at least one lateral resilient ridge  135 , and bricks  140  as described above for the embodiments shown in  FIGS. 1-4 . The formliner  215  also comprises at least one pad  260 , positioned in each recess  105 , each at least one pad  260  having a height of θ measured from where the at least one pad  260  meets the at least substantially planar recess surface  120  to the top of the at least one pad surface  285 . 
     The formliner  215  is preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliner comprises cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprises cured sulfide RTV liquid rubber made from two liquid precursors. The formliner  215  is molded and cured as known in the art. 
     The formliner  215  is preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliner comprises cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprises cured sulfide RTV liquid rubber made from two liquid precursors. The formliner  215  is molded and cured as known in the art. 
     Each at least one pad  260  is preferably unitary with each at least substantially planar recess surface  120 . Each pad  260  extends from each at least substantially planar surface  120  a preselected depth distance θ. The depth distance θ is dependent upon the size of the bricks. For example, for a brick  140  having dimensions of about 7½ inches long by about 3½ inch wide by about ½ inch thick, an exemplary value for 0 is about ⅛ inch. In an alternate embodiment, each at least one pad  260  is made separately from the formliner  215  and is placed in each recess  105  and connected thereto. 
     Each at least one pad  260  may be of any functional geometry, as long as the at least one pad  260  is able to support the entire brick  140  and the superimposed cementitious material  145 .  FIGS. 5-7  illustrate one embodiment of the at least one pad  260 , where the at least one pad  260  extends around the entire perimeter of each at least substantially planar recess surface  120 . Any number of at least one pads  260  may be present in each recess  105  as desired. The use of the at least one pad  260  in each recess  105  reduces the total amount of material required for the formliner  215 . 
     Each pad surface  285  is preferably a substantially randomly preselected pad variance depth distance from the rib plane  125 , such that every substantially randomly preselected pad variance depth distance is not identical to every other substantially randomly preselected pad variance depth distance. The substantially randomly preselected pad variance depth distance for each pad surface  285  is substantially randomly preselected from a preselected pad variance depth distance range. The upper and lower limits of the preselected pad variance depth distance range are dependent upon the thickness of the brick  140  (or other element). As described above for the other embodiments, the smallest value of the pad variance depth distance range cannot be too small or the brick  140  (or other construction element) will not be effectively sealed into the recess  105  by the at least one lateral resilient ridge  130  and the at least one transverse resilient ridge  135 , which can result in cementitious material  145  adhering to the front face  150  of the brick  140 . 
     The largest value of the pad variance depth distance range cannot be too large or the brick (or other construction element) will not extend far enough out beyond the rib plane  125  of the formliner  215  to effectively adhere into the cementitious material  145 . For example, if thin brick  140  is selected for use with a particular formliner  215 , with the brick  140  having dimensions of about 7½ inch long by about 3½ inch wide by about ½ inch thick, the value of 0 is about ⅛ inch being used in the formliner  215  of the present invention, the pad variance depth distance range would be in the range of about ¼ to about ⅛ to achieve proper functioning of the formliner  215 . 
     In a preferred alternate embodiment, each pad variance depth distance is substantially randomly preselected from a preselected set of pad variance depth distances, the set of pad variance depth distances comprising a preselected number of discrete preselected pad variance depth distances. Each pad variance depth distance is substantially randomly preselected such that every substantially randomly preselected pad variance depth distance from the set is not identical to every other substantially randomly preselected pad variance depth distance from the set. In a preferred embodiment, the number of pad variance depth distances in the set is in the range of from about 2 to about 5. In a more preferred embodiment, the number of pad variance depth distances in the set is 4. 
     One exemplary embodiment is shown in  FIGS. 5-7 , where the pad variance depth distance set includes four pad discrete variance depth distances, represented as α, β, Δ, and λ. As in the previous embodiments, in the embodiments shown in  FIG. 5-7 , the largest depth distance is Δ, the next largest depth distance is β, the next largest depth distance is λ, and the shortest depth distance is α.  FIG. 6  is a cross section of  FIG. 5 , showing four separate recesses without bricks, each recess having a different pad variance depth distance, one each of α, β, Δ, and λ. 
     A first recess  220  has a pad variance depth distance of α, such that a pad surface  290  of the at least one pad  265  is a depth distance of α from the rib plane  125 . The at least substantially planar surface  240  is a depth distance of α plus θ from the rib plane  125 . A second recess  225  has a pad variance depth distance of β, such that a pad surface  295  of the at least one pad  270  is a depth distance of β from the rib plane  125 . The at least substantially planar surface  245  is a depth distance of β plus θ from the rib plane  125 . A third recess  230  has a pad variance depth distance of Δ, such that a pad surface  300  of the at least one pad  275  is a depth distance of Δ from the rib plane  125 . The at least substantially planar surface  250  is a depth distance of Δ plus θ from the rib plane  125 . A fourth recess  235  has a pad variance depth distance of λ, such that a pad surface  305  of the at least one pad  280  is a depth distance of λ from the rib plane  125 . The at least substantially planar surface  255  is a depth distance of λ plus θ from the rib plane  125 . 
     Bricks  140  installed into the formliner  215  are shown in cross-section in  FIG. 7 . shows four separate recesses with bricks  140 , each recess again having a pad variance depth distance, one each of α, β, Δ, and λ. Cementitious material  145  is shown in phantom. A first brick  195  is shown positioned against pad surface  290 , which is a depth distance α from the rib plane  125 . A second brick  200  is shown positioned against pad surface  295 , which is a depth distance β from the rib plane  125 . A third brick  205  is shown positioned against pad surface  300 , which is a depth distance Δ from the rib plane  125 . A fourth brick  210  is shown positioned against pad surface  305 , which is a depth distance λ from the rib plane  125 . 
     During normal construction, after the bricks  140 ,  195 ,  200 ,  205 ,  210  are installed in the formliner  215 , cementitious material  145  is poured into a structure, or form as known in the art, against the formliner  215  and bricks  140 ,  195 ,  200 ,  205 ,  210  to create a wall or other structure with the appearance of a hand laid brick wall (or other structure). As the cementitious material  145  cures, the bricks  140 ,  195 ,  200 ,  205 ,  210  are sealed within the cementitious material  145 . Once the cementitious material  145  is sufficiently cured to retain the bricks  140 ,  195 ,  200 ,  205 ,  210 , the formliner  215  is removed from the cementitious material  145  and the bricks  140 ,  195 ,  200 ,  205 ,  210  leaving the bricks  140   195 ,  200 ,  205 ,  210  set within the cementitious material  145 . 
     As is evident from the cementitious material  145  shown in phantom in  FIG. 7 , once the formliner  215  is removed, the brick  205  that was positioned against the deepest pad surface  300  extends the furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  200  that was positioned against the next deepest pad surface  295  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  210  that was positioned against the next deepest pad surface  305  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  195  that was positioned against the shallowest pad surface  290  extends the least out from the cementitious material  145  as measured from rib plane  125 . Such variance in the extensions of the bricks  140 ,  195 ,  200 ,  205 ,  210  out from the cementitious material  145  results in a wall (or other construction element) with the appearance of a hand-laid brick wall rather than the appearance of a brick wall that was manufactured with a conventional formliner. 
     In another alternate embodiment of the present invention, as shown in  FIGS. 8-10 , a formliner  310  is shown with recesses  105 , lateral ribs  110 , transverse ribs  115 , at least substantially planar recess surfaces  120 , a rib plane  125 , at least one lateral resilient ridge  135 , and bricks  140  as described above for the embodiments shown in  FIGS. 1-4 . Each at least substantially planar recess surface  340  is at least substantially coextensive with a recess surface plane  335 . Each recess surface plane  335  is positioned a preselected depth distance κ from the rib plane  125 . Each recess  105  also contains at least one pad  345 , each pad has a pad surface  370 . For the use with brick  140  having dimensions of about 7½ inches long by about 3½ inch wide by about ½ inch thick, an exemplary values for κ is about ⅜ inch. For bricks  140  having different dimensions, the value of κ may be larger or smaller than about ⅜ inch, but is limited by the fact that κ may not be so large that the structural integrity of the formliner  310  is reduced to the point where the formliner  310  ceases to be functional. 
     The formliner  310  is preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliner comprises cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprises cured sulfide RTV liquid rubber made from two liquid precursors. The formliner  310  is molded and cured as known in the art. 
     Each at least one pad  345  is preferably unitary with each at least substantially planar recess surface  340 . In an alternate embodiment, each at least one pad  345  is made separately from the formliner  310  and is placed in each recess  105  and connected thereto. 
     Each pad surface  370  is preferably a substantially randomly preselected pad variance depth distance from the rib plane  125 , such that every substantially randomly preselected pad variance depth distance is not identical to every other substantially randomly preselected pad variance depth distance. The substantially randomly preselected pad variance depth distance for each pad surface  370  is substantially randomly preselected from a preselected pad variance depth distance range. The upper and lower limits of the preselected pad variance depth distance range are dependent upon the thickness of the brick  140  (or other element). As described above for the other embodiments, the smallest value of the pad variance depth distance range cannot be too small or the brick  140  (or other construction element) will not be effectively sealed into the recess  105  by the at least one lateral resilient ridge  130  and the at least one transverse resilient ridge  135 , which can result in cementitious material adhering to the front face  150  of the brick  140 . 
     The largest value of the pad variance depth distance range cannot be too large or the brick (or other construction element) will not extend far enough out beyond the rib plane  125  of the formliner  310  to effectively adhere into the cementitious material  145 . 
     In a preferred alternate embodiment, each pad variance depth distance is substantially randomly preselected from a preselected set of pad variance depth distances, the set of pad variance depth distances comprising a preselected number of discrete preselected pad variance depth distances. In a preferred embodiment, the number of pad variance depth distances in the set is in the range of from 2 to about 5. In a more preferred embodiment, the number of pad variance depth distances in the set is 4. Each pad variance depth distance is substantially randomly preselected such that every substantially randomly preselected pad variance depth distance from the set is not identical to every other substantially randomly preselected pad variance depth distance from the set. 
     One exemplary embodiment is shown in  FIGS. 8-10 , where the pad variance depth distance set includes four discrete pad variance depth distances, represented as α, β, Δ, and λ. As in the previous embodiments, in the embodiments shown in  FIG. 8-10 , the largest depth distance is Δ, the next largest depth distance is β, the next largest depth distance is λ, and the shortest depth distance is α.  FIG. 9  is a cross section of  FIG. 8 , showing four separate recesses without bricks, each recess having a different pad variance depth distance, one each of α, β, Δ, and λ. 
     A first recess  315  has a pad variance depth distance of α, such that a pad surface  375  of at least one pad  350  is depth distance of α from the rib plane  125 . The pad surface  375  is a depth distance of κ minus α from recess surface plane  335 . A second recess  320  has a pad variance depth distance of β, such that a pad surface  380  of the at least one pad  355  is a depth distance of β from the rib plane  125 . The pad surface  380  is a depth distance of κ minus β from the rib plane  125 . A third recess  325  has a pad variance depth distance of Δ, such that a pad surface  385  of the at least one pad  360  is depth distance of Δ from the rib plane  125 . The pad surface  385  is a depth distance of κ minus Δ from the rib plane  125 . A fourth recess  330  has a pad variance depth distance of λ, such that a pad surface  390  of the at least one pad  365  is a depth distance of λ from the rib plane  125 . The pad surface  390  is a depth distance of κ minus λ from the rib plane  125 . 
     Bricks  140  installed into the formliner  310  are shown in cross-section in  FIG. 10 .  FIG. 10  shows four separate recesses with bricks  140 , each recess again having a pad variance depth distance, one each of α, β, Δ, and λ. Cementitious material  145  is shown in phantom. The first brick  195  is shown positioned against pad surface  375 , which is a depth distance α from the rib plane  125 . The second brick  200  is shown positioned against pad surface  380 , which is a depth distance β from the rib plane  125 . The third brick  205  is shown positioned against pad surface  385 , which is a depth distance Δ from the rib plane  125 . The fourth brick  210  is shown positioned against pad surface  390 , which is a depth distance λ from the rib plane  125 . 
     During normal construction, after the bricks  140 ,  195 ,  200 ,  205 ,  210  are installed in the formliner  310 , cementitious material  145  is poured into a structure, or form as known in the art, against the formliner  310  and bricks  140 ,  195 ,  200 ,  205 ,  210  to create a wall or other structure with the appearance of a hand laid brick wall (or other structure). As the cementitious material  145  cures, the bricks  140 ,  195 ,  200 ,  205 ,  210  are sealed within the cementitious material. Once the cementitious material is sufficiently cured to retain the bricks  140 ,  195 ,  200 ,  205 ,  210 , the formliner  310  is removed from the cementitious material  145  and the bricks  140 ,  195 ,  200 ,  205 ,  210  leaving the bricks  140 ,  195 ,  200 ,  205 ,  210  set within the cementitious material  145 . 
     As is evident from the cementitious material in phantom  145 , once the formliner  310  is removed, the brick  205  that was positioned against the deepest pad surface  385  extends the furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  200  that was positioned against the next deepest pad surface  380  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  210  that was positioned against the next deepest pad surface  390  extends the next furthest out from the cementitious material  145  as measured from rib plane  125 . The brick  195  that was positioned against the shallowest pad surface  375  extends the least out from the cementitious material  145  as measured from rib plane  125 . Such variance in the extensions of the bricks  140 ,  195 ,  200 ,  205 ,  210  out from the cementitious material  145  results in a wall (or other construction element) with the appearance of a hand-laid brick wall rather than the appearance of a brick veneer wall that was manufactured with a conventional formliner. 
     Another embodiment of the formliners the present invention is shown in  FIG. 11  and  FIG. 12 . Formliners are regularly modular in assembly, such that several formliners are butted up against one another and enclosed by a suitable framework in order to achieve the desired result. For example, if the formliners are produced such that they are 4′ high by 8′ long, but the length of a wall that is to be assembled using the formliner is 24′ long, then three separate formliners would need to be laid side by side in order to achieve the 24′ length. Ordinarily, it is desired to cast relatively large panels and a number of the templates are butted together When two formliners  400 ,  405  are assembled to lay side by side, a joint  495  is present between the two formliners. The present invention limits that amount of cementitious material that will flow between and/or through the formliners  400 ,  405  during use. 
     The formliners  400 ,  405  are preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliners comprise cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprise cured sulfide RTV liquid rubber made from two liquid precursors. The formliners  400 ,  405  are molded and cured as known in the art. 
     Two formliners  400 ,  405  are shown generally in a perspective view in  FIG. 11  with their joint  495  exploded so that it can readily be seen how the two formliners  400 ,  405  are joined together during use. The formliners  400 ,  405  are formed with a series of recesses  410 , which are separated by and defined by lateral ribs  440  and interconnecting transverse ribs  445 ,  450 . Recesses  410 ,  415 ,  420 ,  425 ,  430  are shown in  FIG. 11  and  FIG. 12  in a brick running bond configuration. Such running bond configuration is only used to illustrate the features of the present invention and is not intended to limit the scope of the invention. Any other formliner configuration known in the art may also be used with the present invention, such as, for example flemish bond, basket weave, herringbone, etc. At the base of each recess  410 ,  415 ,  420 ,  425 ,  430  is an at least substantially planar recess surface  455 . The lateral ribs  440  and transverse ribs  445 ,  450  extend from the at least substantially planar recess surfaces  455  to define the recesses  410 . 
     Each of the lateral ribs  440  is provided with at least one resilient protrusion or ridge  460 , on every side of the lateral ribs  440  facing a recess  410 ,  415 ,  420 ,  425 ,  430 , which extends from the lateral ribs  440  into the recesses  410 ,  415 ,  420 ,  425 ,  430 . In addition, each of the transverse ribs  445 ,  450  is provided with at least one protrusion or ridge  465 , on every side of the transverse ribs  445 ,  450  facing a recess  410 ,  415 ,  420 ,  425 ,  430 , which also extend from the transverse ribs  445 ,  450  into the recesses  410 ,  415 ,  420 ,  425 ,  430 . These at least one resilient protrusions or ridges  460 ,  465  function as described above as for the at least one resilient protrusion or ridge  130 ,  135  for  FIGS. 1-4 . In a preferred embodiment, a plurality of resilient protrusions or ridges  460 ,  465  are present on every side of the lateral ribs  440  and transverse ribs  445 ,  450  facing a recess  410 ,  415 ,  420 ,  425 ,  430 . 
     While the present invention is described using rectangular recesses  410 , which are designed to receive rectangular bricks (or other construction elements), it should be understood that the present invention works with any shape or size of brick or other element to be assembled into a wall or other construction element. In normal wall construction, for which the running bond configuration is selected, most of the recesses are, or as explained further herein when the formliners  400 ,  405  are butted next to each other during use, become, enclosed full sized recesses, which are designed to receive a full sized brick (or other construction element). However, as is known in the art, some of the recesses at the end of the formliners will be enclosed half sized recesses to receive half sized bricks (or other elements). 
     Lateral exterior edges  470  and transverse exterior edges  475 ,  480  form the exterior boundaries of the formliners  400 ,  405  at and adjacent to the joint  495 . The formliners  400 ,  405  are shown as generally in the form of a rectangular prism, but other shapes are also covered by the present invention, including more complex shapes that would be required due to complex building (or other structure) designs. The structure of the first formliner  400  at and adjacent to the transverse exterior edge  475  at the joint  495  is distinct from the structure of the second formliner  405  at and adjacent to the transverse exterior edge  480  at the joint  495 . 
     The formliner  400 ,  405  structure at and adjacent to transverse exterior edges  475 ,  480  are configured so that the pattern of the recesses  410 , shown in  FIG. 11  and  FIG. 12  as a running bond pattern, of the formliners  400 ,  405  is continuous across the joint  495  and so as to limit the flow of cementitious material through the joint  495  during the use of the formliners  400 ,  405 . Such limitation of the flow of cementitious material through the joint  495  is accomplished through the specific configurations of the areas at and adjacent to the transverse exterior edges  475 ,  480 . 
     As a function of the exemplary running bond configuration and the straight joint  495 , the first formliner  400  has two types of recesses  415 ,  425  at and adjacent to the joint  495 . The first type of recess  415  is a full sized recess, which is fully enclosed by lateral ribs  440  and transverse ribs  445 ,  450  including exterior transverse ribs  450  located at the joint  495 . At the joint  495 , the transverse ribs  450  have exterior edges  485 , each of which have at least one exterior transverse resilient ridge  490 , which extends away from the recess  415  which is enclosed, in part, by the exterior transverse rib  450 . The second type of recess  425  is only partially enclosed by two lateral ribs  440  and one transverse rib  445  and is slightly more than half the size of a full sized recess  415 . In a preferred embodiment, there are a plurality of exterior transverse resilient ridges  490 . 
     The second formliner  405  also has two types of recesses at and near the joint  495 . The first type of recess  420  is a full sized recess, but is only partially enclosed by two lateral ribs  440  and one transverse rib  445 . The second type of recess  430  is also only partially enclosed by two lateral ribs  440  and one transverse rib  445  and is slightly less than half the size of a full sized recess  420 , making the recess  430  smaller than the larger opposite recess  425 . 
     As shown in  FIG. 12 , when the two formliners  400 ,  405  are butted next to one another during use, the formliners  400 ,  405  are aligned so that the exterior transverse ribs  450  of the first formliner  400  completes the enclosure of the first type of recesses  420  in the second formliner  405 , creating a fully enclosed recess  500 , which results in the at least one exterior transverse resilient ridge  495  serving as an at least one resilient ridge for the enclosed recess  500 . The formliners  400 ,  405  are also aligned so that the second types of recesses  425 ,  430  matingly abut each other to create a fully enclosed full sized recess  505 . 
     When bricks (or other elements)  510 ,  515  are installed as known in the art into the abutted formliners  400 ,  405  during use, the bricks are snugly and sealingly received by the recesses  500 ,  505  substantially the entire joint  495  is sealed against cementitious material passing through the joint  495 . For exemplary purposes, only two bricks  510 ,  515  are shown, although during use all recesses would contain bricks (or other elements). For the portion of the joint  495  positioned at the location of the now fully enclosed recess  500 , the at least one exterior transverse resilient ridge  490  acts as a seal against the brick present in a now fully enclosed recess  500 , preventing the flow of cementitious material into and/or through that portion of the joint  495 . 
     For the portion of the joint  495  located between the larger partial recess  425  of the first formliner  405  and the smaller partial recess  430  of the second formliner  405 , a brick  515  itself overlaps the joint  495  in the now full sized recess  505 , with the brick  515  sealing the portion of the joint  495  that runs through recess  505 , preventing the flow of cementitious material into and/or through that portion of the joint  495 . The prevention of such flow of cementitious material is important as it reduces and/or eliminates the excess cementitious material that otherwise covers the bricks (or other elements) after the formliners  400 ,  405  are removed from the wall or other structure. Such excess cementitious material must be cleaned off of the bricks in order to create a proper appearance, adding extra expense to the construction. 
     Another embodiment of the formliners of the present invention is shown in  FIG. 13  and  FIG. 14 . As mentioned above, formliners are regularly modular in assembly, such that several formliners are butted up against one another and enclosed by a suitable framework in order to achieve the desired result. For example, if the formliners are produced such that they are 4′ high by 8′ long, but the height of a wall that is to be assembled using the formliners is 12′ high, then three separate formliners would need to be laid top to bottom to achieve the 12′ height. Ordinarily, it is desired to cast relatively large panels and a number of the templates are butted together. When two formliners  600 ,  605  are assembled to lay top to bottom, a joint  695  is present between the two formliners. The present invention limits the amount of cementitious material that will flow between and/or through the formliners  600 ,  605  during use. 
     The formliners  600 ,  605  are preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliners comprise cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprise cured sulfide RTV liquid rubber made from two liquid precursors. The formliners  600 ,  605  are molded and cured as known in the art. 
     Two formliners  600 ,  605  are shown generally in a perspective view in  FIG. 13  with their joint  695  exploded so that it can readily be seen how the two formliners  600 ,  605  are joined together during use. The formliners  600 ,  605  are formed with a series of recesses  610 ,  615 ,  620 ,  625 ,  630 , which are separated by and defined by lateral ribs  640 ,  650  and interconnecting transverse ribs  645 . The recesses  610 ,  615 ,  620 ,  625 ,  630  are shown in  FIGS. 13 and 14  in a brick running bond configuration. Such running bond configuration is only used to illustrate the features of the present invention and is not intended to limit the scope of the invention. Any other formliner configuration known in the art may also be used with the present invention, such as, for example such as, for example flemish bond, basket weave, herringbone, etc. At the base of each recess  610 ,  615 ,  620 ,  625 ,  630  is an at least substantially planar recess surface  655 . The lateral ribs  640 ,  650  and transverse ribs  645  extend from the planar recess surfaces  655  to define the recesses  610 ,  615 ,  620 ,  625 ,  630 . 
     Each of the lateral ribs  640  is provided with at least one resilient protrusion or ridge  660 , on every side of the lateral ribs  640 ,  650  facing a recess  610 ,  615 ,  620 ,  625 ,  630 , which extends from the lateral ribs  640 ,  650  into the recesses  610 ,  615 ,  620 ,  625 ,  630 . In addition, each of the transverse ribs  645  is provided with one or more resilient protrusions or ridges  665 , on every side of the transverse ribs  645  facing a recess  610 ,  615 ,  620 ,  625 ,  630 , which also extend from the transverse ribs  645  into the recesses  610 ,  615 ,  620 ,  625 ,  630 . These at least one resilient protrusions or ridges  660 ,  665  function as described above as for  FIGS. 1-4 . In a preferred embodiment, a plurality of resilient protrusions or ridges  665  are present on every side of the lateral ribs  640 ,  650  and transverse ribs  645  facing a recess  610 ,  615 ,  620 ,  625 ,  630 . 
     While the present invention is described using rectangular recesses  610 ,  615 ,  620 ,  625 ,  630 , which are designed to receive rectangular bricks  705 ,  720 ,  725  (or other construction elements), it should be understood that the present invention works with any shape or size of brick or other element to be assembled into a wall or other construction element. In normal wall construction, for which the running bond configuration is selected, most of the recesses are, or as explained further herein when the formliners  600 ,  605  are butted next to each other during use, become enclosed full sized recesses  710 , which are designed to receive a full sized brick (or other construction element). However, as is known in the art, some of the recesses at the end of the formliners will be enclosed half sized recesses  625 ,  630  to receive half sized bricks  705 ,  725  (or other elements) as shown in  FIG. 14 . 
     Lateral exterior edges  675 ,  680  and transverse exterior edges  670  form the exterior boundaries of the formliners  600 ,  605  at and adjacent to the joint  695 . The formliners  600 ,  605  are shown as generally in the form of a rectangular prism, but other shapes are also covered by the present invention, including more complex shapes that would be required due to complex building (or other structure) designs. The structure of the first formliner  600  at and adjacent to the lateral exterior edge  675  at the joint  695  is distinct from the structure of the second formliner  605  at and adjacent to the lateral exterior edge  680  at the joint  695 . 
     The formliner  600 ,  605  structure at and adjacent to lateral exterior edges  675 ,  680  are configured so that the pattern of the recesses  610 ,  615 ,  620 ,  625 ,  630 , shown in  FIG. 13  and  FIG. 14  as a running bond pattern, of the formliners  600 ,  605  is continuous across the joint  695  and so as to limit the flow of cementitious material through the joint  695  during the use of the formliners  600 ,  605 . Such limitation of the flow of cementitious material through the joint  695  is accomplished through the specific configurations of the areas at and adjacent to the lateral exterior edges  675 ,  680 . 
     As a function of the exemplary running bond configuration and the straight joint  695 , the first formliner  600  has one type of recesses  615  at and adjacent to the joint  695 . The first formliner also has another type of recess, namely a half-recess  625 , but half-recess  625  is not located at the joint  695 . The first type of recess  615  is a full sized recess, which is fully enclosed by lateral ribs  640 ,  650  and transverse ribs  645  including exterior lateral rib  650  located at the joint  695 . At the joint  695 , the lateral rib  650  has an exterior edge  675 , and which at least one exterior transverse resilient ridge  690 , which extends away from the recess  615  which are enclosed, in part, by the exterior lateral rib  650 . In a preferred embodiment, there are a plurality of exterior transverse resilient ridges  690 . In an alternate embodiment, there is one exterior transverse resilient ridge  690 . 
     The second formliner  605  has two types of recesses at and near the joint  695 . The first type of recess  620  is a full sized recess, but is only partially enclosed by two transverse ribs  645  and one lateral rib  640 . The second type of recess  630  is also only partially enclosed by two transverse ribs  645  and one lateral rib  640  and is about half the size of a full sized recess  620 . 
     As shown in  FIG. 14 , when the two formliners  600 ,  605  are butted next to one another during use, the formliners  600 ,  605  are aligned so that the exterior lateral rib  650  of the first formliner  600  completes the enclosure of the first and second types of recesses  620 ,  630  in the second formliner  605 , creating fully enclosed recesses  710 , which results in the at least one exterior lateral resilient ridge  690  serving as an at least one resilient ridge for the enclosed recesses  710 . 
     When bricks (or other elements)  720 ,  725  are installed as known in the art into the abutted formliners  600 ,  605  during use, at least substantially the entire joint  695  is sealed against cementitious material passing through the joint  695 . For exemplary purposes, only two bricks  720 ,  725  are shown at the joint  695 , although during use all recesses would contain bricks (or other elements). For the portion of the joint  695  positioned at the location of the now fully enclosed recesses  710 , the at least one exterior transverse resilient ridge  690  acts as a seal against the brick present in a now fully enclosed recess  700 , preventing the flow of cementitious material into and/or through that portion of the joint  695 . For the remaining portion of the joint  695 , the at least one exterior lateral resilient ridge  690  acts as a seal against the lateral exterior edge  680 . 
     The prevention of such flow of cementitious material is important as it reduces and/or eliminates the excess cementitious material that covers the bricks (or other elements) after the formliners  600 ,  605  are removed from the cured wall or other structure. Such excess cementitious material must be cleaned off of the bricks in order to create a proper appearance, adding extra expense to the construction. 
     The formliner set shown in  FIG. 11  and  FIG. 12  is exemplary for formliners where the joint  495  is positioned transversely. The formliner set shown in  FIG. 13  and  FIG. 14  is exemplary for formliners where the joint  695  is positioned laterally. As provided by the present invention, any formliner may contain both lateral joints  495  and transverse joints  695  as set forth in  FIGS. 11-14 , providing the ability to use multiple formliners to be used modularly together to create walls and other architectural objects having both significant heights and widths. Such formliners may combine the elements of exemplary formliners  400 ,  405 ,  600 , and  605  described herein to achieve the desired architectural result. 
     Another embodiment of a formliner  800  of the present invention is shown in  FIG. 15  in a fragmentary view in perspective and a cross-section of the formliner of  FIG. 15  taken along line  15 - 15  is shown in  FIG. 16 . A formliner  800  is shown generally in a perspective view. A main portion  850  of formliner  800  is preferably manufactured from an elastomeric material, such as rubber or any other resilient polymer of sufficient strength that it is compatible with cementitious material. In a preferred embodiment, the formliner comprises cured polymer made from liquid precursors. In a most preferred embodiment, the formliner comprises cured sulfide RTV liquid rubber made from two liquid precursors. The formliner  800  is molded and cured as known in the art. 
     The formliner  800  is formed with a series of recesses  805 , which are separated by and defined by lateral ribs  810  and interconnecting transverse ribs  815 . The recesses  805  are shown in the figures in a brick running bond configuration, the configuration in which bricks are conventionally applied to walls. Such running bond configuration is only used to illustrate the features of the present invention and is not intended to limit the scope of the invention. Any other formliner configuration known in the art may also be used with the present invention, such as, for example flemish bond, basket weave, herringbone, etc. At the base of each recess  805  is a at least substantially planar recess surface  820 . The lateral ribs  810  and transverse ribs  815  extend from the at least substantially planar recess surfaces  820  to a rib plane  825 . 
     Each of the lateral ribs  810  is provided with at least one resilient protrusion or ridge  830 , on every side of the lateral ribs facing a recess  805 , which extend from the lateral ribs  810  into the recesses  805 . In addition, each of the transverse ribs  815  is provided with at least one resilient protrusion or ridge  835 , on every side of the transverse ribs  815  facing a recess  805 , which also extends from the lateral ribs  810  into the recesses  805 . As known in the art, the at least one ridges  830 ,  835  are used engage and seal an adjacent surface of a brick (not shown) or other similar construction element, such as stone, tiles, stone slabs or other similar block elements, to prevent cementitious material, from flowing into the interior of the recess  805  and contacting the front faces of the bricks (or other element). The recess  805  has a geometry such that is able to snugly receive a brick (or other element). Preferably the structure and number of the at least one lateral ridge  830  is substantially identical to the structure and number of the at least one transverse ridge  835 . Optionally, the structure and number of the at least one lateral ridge  830  is substantially identical to the structure and number of the at least one transverse ridge  835 . It is preferred that there are from one to about six lateral ridges  830  present on each lateral rib  810  and that there are from one to about six transverse ridges  835  present on each transverse rib  815  for each recess  805 . In a more preferred embodiment there are from one to about four lateral ridges  830  present on each lateral rib  810  and from one to about four transverse ridges  835  present on each transverse rib  815  for each recess. 
     The formliner comprises two separate portions, a main portion  850  and a backing  855 , which adds additional structural support to the main portion  850 . The backing  855  is preferably cast into the formliner  800  during manufacture as known in the art. The backing  855  has a geometry such that the backing  855  fits within the main portion  850  without interfering with the function of the recesses  805 . Alternately, the backing  855  may be glued or otherwise sealed into the formliner  800  after production of the main portion  850 . 
     Generally the backing  855  has a generally similar geometry to that of the formliner  800 . As shown in the exemplary embodiment of  FIG. 15  and  FIG. 16 , both the formliner  800  and the backing  855 , which can be composed of wood or plywood, are both generally in the shape of a rectangular prism. The dimensions of the backing  855  are preferably smaller than the dimensions of the formliner  800 , as the main portion  850  of the formliner  800  is positioned around the periphery of the backing  855 . As an example, if the formliner is about 4′ long by about 8′ wide by about 1¼ inch thick, then an functional backing would be about 3′ 11″ wide by about 7′ 11″ long by about 0.75″ thick. The backing  855  comprises a material selected from the group consisting of plywood, wood, metal, plastic, a non-wood composite material, and combinations thereof and is less flexible than the formliner  800 . Alternately, the backing  855  can be constructed of any composite material having sufficient strength and thickness. The backing  855  is preferably comprised of plywood. 
     As shown in  FIG. 15  and  FIG. 16 , the backing  855  comprises sidewalls  865 , a top surface  860  and a bottom surface  870 . The backing also has a notch  875 . The notch  875  extends at least through at least a substantial portion of one of the sidewalls  865 . The presence of the notch  875  enables the backing  855  to be held into the formliner  800  more readily than if the formliner  800  did not have a notch  875 . In a preferred embodiment, the notch is present in the entire portion of all the sidewalls  865 . 
     It is to be understood that the at least one notch  875  may be of any functional geometry, as long as it makes it less likely that the backing  855  will be dislodged from the main portion  850  during formliner  800  use and as long as the presence of the notch does not reduce the structural stability and/or the structural integrity of the formliner  800 . In a preferred embodiment, the notch  875  has a substantially rectangular cross-section  880 . In a preferred embodiment, the number of notches  875  is preselected from the range of from 1 to about 6. In a more preferred embodiment, there is one contiguous notch  875 . 
     In a preferred embodiment, where the main portion  850  is a polymeric material made from liquid precursors some of polymeric precursor of material for the main portion  850  flows into at least the notch  875  during the manufacture of the formliner  800  and cures within the notch  875 . During use, as the formliner  800  is manipulated, the backing  855  is less likely to be dislodged from the main portion  850  as an extension  885  of the main portion  850  extends into the backing  855 . 
     In a preferred embodiment, the backing  855  comprises at least one layer of plywood and has a thickness in the range of about ½ inch to about 3 inches. In a more preferred embodiment, the number of layers of plywood is in the range of from 1 to about 6. In an even more preferred embodiment, the number of layers of plywood is in the range of from 1 to 2. In a most preferred embodiment, the backing  855  has a thickness of about 0.75 inch and there is one notch  875  having a cross-sectional area of about 0.125 inch. Preferably, for the wood and plywood embodiments, the ratio of the cross-sectional thickness to the thickness of the backing is substantially proportional to both the height of the notch and the depth distance of the notch. For a backing  855  which is about 3 inches thick, the notch could be as wide as about 2 inches and as deep as about 1 inch, while for a backing having a thickness of about ¾ inch, the notch could be as wide as about ¼ inch and as deep as about ½ inch without a reduction in structural stability or structural integrity. In a preferred embodiment in which a number of layers of plywood are used, there is preferably one notch  875  through all of the sidewalls  865  of a layer of plywood that is positioned furthest from the recesses  805 . 
     While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.