Patent Document

RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. Non-Provisional patent application Ser. No. 11/977,503 filed Oct. 24, 2007 and entitled “Material Curing Constructions and Methods for Curing Material.” This application also claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application Ser. No. 61/069,361 filed Mar. 14, 2008 and entitled “Material Curing Constructions and Methods for Curing Material.” 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates to the curing of materials and more particularly construction materials such as concrete. 
       BACKGROUND 
       [0003]    Cured construction materials such as concrete play an important, if not necessary, role in modern construction. However, the use of concrete can limit the architectural features of a construction, leaving the building cold and aesthetically displeasing. 
       SUMMARY OF THE DISCLOSURE 
       [0004]    Form inserts are provided that can include a flexible sheet having multiple ribs extending from at least one surface of the sheet. 
         [0005]    Methods for curing material within a form are provided that can include expanding a sheet over an interior portion of one form defining a perimeter of material to be cured. The sheet can include ribs extending from a surface of the sheet to within the perimeter. The material to be cured can be provided to within the form, with the material receiving at least a portion of the ribs of the sheet. The material can be cured, and the sheet removed from the cured material. 
         [0006]    Column form inserts are also provided that can include a plurality of circular ribs defining a perimeter of a column form. The ribs can be coupled to one another by interconnecting members to form a frame, for example. 
         [0007]    A method of producing a form insert is also provided that can include providing a sheet of flexible material and adhering a flexible mesh to the sheet, with the flexible mesh forming ribs extending from at least one surface of the sheet. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]    Embodiments of the disclosure are described below with reference to the following accompanying drawings. 
           [0009]      FIG. 1  is a form insert and orchestration of use of same according to an embodiment. 
           [0010]      FIG. 2  is form insert production apparatus according to an embodiment. 
           [0011]      FIG. 3  is form material according to an embodiment. 
           [0012]      FIG. 4  is a form insert and orchestration of use of same according to an embodiment. 
           [0013]      FIG. 5  is a detail of a coupled form insert according to an embodiment. 
           [0014]      FIG. 6  is a form insert according to an embodiment. 
           [0015]      FIG. 7  is a form insert and orchestration of use of same according to an embodiment. 
           [0016]      FIG. 8  is a form according to an embodiment. 
           [0017]      FIG. 9  is another view of the form of  FIG. 8  according to an embodiment. 
           [0018]      FIG. 10  is a form according to an embodiment. 
           [0019]      FIG. 11  is a form according to an embodiment. 
           [0020]      FIG. 12  is a form according to an embodiment. 
           [0021]      FIG. 13  is a form according to an embodiment. 
           [0022]      FIG. 14  is a form according to an embodiment. 
       
    
    
     DESCRIPTION 
       [0023]    This disclosure is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8). 
         [0024]    Material curing constructions and methods for curing material are provided with reference to  FIGS. 1-14 . Referring to  FIG. 1 , curing construction  10  is shown that includes a flexible sheet  12  having multiple ribs  14  extending from at least one surface of the flexible sheet. Sheet  12  can be constructed of a polymeric material such as polyethylene. Sheet  12  may be from about 3 mils to about 20 mils in thickness. Sheet  12  may also be a scrim reinforced film. Ribs  14  can also be constructed of a polymeric material such as polyethylene/EPTM. Ribs  14  may extend from the surface of flexible sheet  12  a sufficient amount to engage a material to be cured and form a depression therein upon removal of construction  10  from the cured material. Ribs  14  can extend from about 1/16 inch to about ½ inch. According to an example embodiment, ribs  14  are configured to form a mesh of material, and according to another example embodiment, ribs  14  can be configured to form a decorative pattern. In another embodiment, ribs  14  can be configured to form an architectural feature. 
         [0025]    Referring to  FIG. 1 , construction  10  can be expanded over an interior portion of one form defining a perimeter of a material to be cured. Consistent with the field of art, forms can be used to define a boundary for curing materials such as concrete or any other building construction materials. In this embodiment, the form consists of a semi-, or almost completely flat substrate that forms a perimeter of the material to be cured. As is shown in  FIG. 1 , construction  10  can be placed against form  16 , and construction  10  can be configured with ribs  14  extending from a surface of the sheet within the perimeter defined by the form. In accordance with exemplary methods of curing material, material to be cured within the form can be provided, and the material can receive at least a portion of ribs  14  of sheet  10 . The material can then be cured and the sheet removed from the material. 
         [0026]    Referring to  FIG. 1  again, upon removal of construction  10 , ribs  14  provide openings  20  within cured material  18 . According to an additional example embodiment, additional materials can be provided between the material to be cured and construction  10  to provide even more additional architectural features. For example, these materials can be provided to demonstrate peaks and/or valleys within the material. Exemplary materials include corrugated paper, for example, or any rough surface materials that can imprint an architectural feature. 
         [0027]    Referring to  FIG. 2 , an example apparatus  30  for preparing construction  10  is shown. Apparatus  30  can include at least two feed rollers, or as shown, at least three feed rollers. Feed rollers  32 ,  34 , and  36  can be operatively configured across forming bed  38 , which can be placed below ceiling apparatus  40 , and then upstream of receiving roll  42 . According to an exemplary embodiment, apparatus  30  can be used to produce a form insert, and part of the construction can include providing a sheet of flexible material from roller  32  and adhering a flexible mesh from roller  34  to the sheet. According to an exemplary embodiment, the flexible mesh can form ribs extending from at least one surface of the sheet. The adhering process can be formed utilizing adhering apparatus  40 . For example, adhering apparatus  40  can be a heat supply that melts pliable polymeric material from roller  32  engaging mesh material from roller  34 . Alternatively, mesh material  34  can be pliable and adhere to flexible material  32  utilizing adhering apparatus  40 . According to an example embodiment, at least one of the two rolls of material to be adhered together can be oriented above the other rolls of material. For example, roll  34  can be oriented above roll  32  in relation to forming bed  38 . According to another embodiment, the adhering process can encase mesh from roll  34  within the flexible material from roll  32 . 
         [0028]    Referring to  FIG. 3 , an example sheet  44  is shown that includes scrim material  45  within polymeric materials  46  and  47 . Scrim material  45  can include a webbing such as nylon or even cotton webbing. Polymeric materials  46  and  47  can either or both be polyethylene, for example. 
         [0029]    Referring to  FIGS. 4 and 5 , another embodiment of the present disclosure is provided. Form insert  50  can be configured to be provided in folded sheets, for example, to conserve storage space at the construction site. As such, these sheets can be stacked on top of one another and stored away in relatively small spaces until needed for use. Sheets  50  can then be unfolded and then aligned in a cylindrical fashion and as aligned, they can form an insert to be provided within a form to house material to be cured. As an example embodiment, forms  50  can include ribs  54  defining a perimeter of the columnar form. The ribs can be coupled to one another by interconnecting members to form a frame. For example, opposing ends of form  50  can be coupled to one another to form a cylindrical construction. As such, upon material curing, columns can be provided that can include architectural features such as indentations outlining a brick construction. Indentations  60  can be consistent with ribs  54 , for example. 
         [0030]    Referring to  FIG. 5 , another example embodiment for the coupling of opposing ends of material  50  is shown. As can be seen, portion  66  of material  50  can form a complimentary hook portion to a hook portion of portion  64  of material  50 . These hooks can be aligned together and compliment one another, engaging one another at portion  62 , for example. 
         [0031]    Referring to  FIG. 6 , and still another embodiment, construction  70  can include a frame or mesh of ribs that can be aligned within a form  72  having cured material therein. According to an exemplary embodiment and referring to  FIG. 7 , construction  70  can be placed within a form  72  and then upon curing of material  74 , the construction  70  can be removed, as well as form  72 , to provide a column  74  of the cured material having exposed architectural features. 
         [0032]    Referring to  FIGS. 8 and 9  another form embodiment is shown as form  80 . Form  80  can be comprised of scrim reinforced film  82 . The film can have a scrim of a fabric such as nylon and polymeric component such as polyurethane, polyvinylchloride, and/or polyethylene. The sheet may be able to withstand tensile loads of 1,000 psi without bursting. 
         [0033]    Referring to  FIG. 9 , form  80  may be formed using heat sealing. For example, seal tape  84  may be applied to abutting ends of film  82 , and heat applied to couple abutting ends of film  82  constructing a tubular form. At least some advantages utilizing embodiments of these forms include:
       the film of the form can be folded, cut and reused between construction jobs with limited clean up and without application of release agents;   the film is much stronger than the pressed board currently used; and   the film leaves a smooth finish surface according to example applications.       
 
         [0037]    Furthermore, form  80  of film  82  can be self-supporting without additional supporting material. However, with reference to  FIG. 10  an embodiment is depicted that includes form  100  constructed of film  102  having support material  104  extending therefrom. According to example embodiments, material  104  can be a scrim reinforced film as well and can be coupled to a lower portion of form  100 . Material  104  can be hot melted, sewn, or even latched to the lower portion. In the shown embodiment, material  104  extends the entire perimeter defined by the lower portion. However, alternative embodiments are contemplated in which a plurality of individual members extend from the lower portion. Openings  106  can be in material  104  and configured to receive spikes that may facilitate the coupling of the form to the surface which may further facilitate the self-support of form  100 . 
         [0038]    Referring to  FIG. 11  another embodiment of the form of the present disclosure is provided with reference to form  110  which includes a taper portion  118  between material  114  and film  112 . Portion  118  can facilitate the formation of an additional supportive footing when preparing concrete pillars using form  100 . 
         [0039]    Referring to  FIG. 12 , yet another embodiment of the form of the present disclosure is provided with reference to form  120  which includes architectural decorative material  124  within film  122 . Form  120  is also coupled to construct a cylindrical form with metal latches  126 . Complimentary portions of latches  126  can be affixed to opposing abutting ends of film  122  and clasp to construct a cylinder. 
         [0040]    Referring to  FIGS. 13 and 14  still additional embodiments of the disclosed forms are depicted. Referring to  FIG. 13  form  130  includes film  132  coupled to base  134 . Base  134  can also be constructed of scrim reinforced polymer but base  134  is configured to contain support/ballast materials such as water and/or sand. Ballast materials may be provided to within opening  136  to fill a void between the configured film of base  134 . Referring to  FIG. 14 , both film  142  and base  144  of form  140  may be configured to contain water and or sand to further stabilize form  140 . 
         [0041]    With reference to an additional embodiment, form  120  can be configured with both upper (not shown) and lower flanges. These flanges can include openings aligned between the flanges to receive plates. Individual supports, such as posts can be configured to extend between the plates and support form  120  in its upright configuration. 
         [0042]    In compliance with the statute, embodiments of the invention have been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the entire invention is not limited to the specific features and/or embodiments shown and/or described, since the disclosed embodiments comprise forms of putting the invention into effect.

Technology Category: 4