MOLD SYSTEMS, DEVICES, AND METHODS FOR FORMING STRUCTURES USING HYDROPHOBIC MOLDING SUBSTANCES

Abstract

Systems, methods, and articles of manufacture provide for a mold system for molding structures (e.g., sand castles) from one or more various types of molding substances (e.g., hydrophobic sand). In one embodiment, a mold system comprises a hinged mold comprising at least two mold sections, each mold section joined by a hinge to at least one other mold section. In one embodiment, the mold system may comprise a mold cap, a removable joining key, and/or a molding tool comprising at least one compactor portion.

Description

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains material, including but not limited to the designs of described mold components and molded structures, that is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in U.S. Patent and Trademark Office patent files or records (or those of other patent offices), but otherwise reserves all copyright rights whatsoever.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of priority of U.S. Provisional Patent Application No. 63/219,357 filed Jul. 7, 2021, entitled “MOLDING SYSTEM FOR MOLDABLE SANDS,” the contents of which are incorporated herein by reference in the present application.

FIELD OF THE INVENTION

The present invention relates to systems and methods for creating structures using hydrophobic molding substances, in particular, hydrophobic moldable sands and other hydrophobic molding substances.

BACKGROUND

Despite the popular interest in hydrophobic and moldable sands (e.g., Kinetic Sand™ moldable sand), current play molds are not optimized for the characteristics and/or the molding environment (e.g., tabletops) for molding structures from moldable sands. In particular, current play molds are not optimized for creating structures having a relatively smaller form factor, having fine detail, for indoor use and/or for use on tabletops.

One issue with existing molds for forming structures of hydrophobic molding substances (e.g., hydrophobic sands or snows) is that a vacuum may be created inside of the mold, making it difficult to separate the mold from the molded structure. Packing or otherwise compacting a molding substance in the mold is often desirable for creating a sturdier structure, but removing more air from the molding substance in this way increases the potential for creating a vacuum in the mold. In some cases, the created vacuum may be strong enough to resist removal of the mold from the structure (or vice versa), and in some cases the vacuum may even retain at least some of the molding substance in or on the mold during separation, or may otherwise cause the structure to break or lose structural integrity when separated from the mold.

This vacuum issue exists even with molds configured to be removed vertically, when gravity is available to act against the vacuum and assist in the separation process. For example, a created vacuum may still be strong enough to break a structure when a user attempts to remove a mold vertically (e.g., lifting an inverted concave mold off a sand castle). If the vacuum is strong enough, there is also the potential issue that when a user lifts a mold to remove it, she will lift the entire structure (i.e., still in the mold) from its intended place, creating a risk that the structure will separate above a surface, drop, and break on impact. Another issue with some types of vertically-removed molds (e.g., “fill-and-flip molds”) is that it is difficult to lift such molds without hitting and damaging the structure just created. A mold designed to be removed vertically is limited to forms that generally taper upward and do not have higher structural elements that are farther from a central axis than lower structural elements.

BRIEF DESCRIPTION OF THE DRAWINGS

An understanding of embodiments described in this disclosure and many of the related advantages may be readily obtained by reference to the following detailed description when considered with the accompanying drawings, of which:

FIG. 1 is a diagram of a mold system according to an embodiment of the present invention;

FIG. 2 is a diagram of a mold system according to an embodiment of the present invention;

FIG. 3 is a diagram of a mold system according to an embodiment of the present invention;

FIG. 4 is a diagram of a molding tool according to an embodiment of the present invention;

FIG. 5 is a diagram of a joining key according to an embodiment of the present invention;

FIG. 6A is a diagram of a mold system according to an embodiment of the present invention;

FIGS. 6B, 6C, 6D, 6E, and 6F are diagrams of an example process of using a mold system according to an embodiment of the present invention; and

FIGS. 7A, 7B, 7C, and 7D are diagrams of components of a molding system according to an embodiment of the present invention.

DETAILED DESCRIPTION

A. Introduction

So that the manner in which the features and advantages of the embodiments of products and methods may be understood in more detail, a more particular description of the embodiments of products and methods may be had by reference to the drawings, which form a part of this specification. It is to be noted, however, that the drawings illustrate only various embodiments of the embodiments of products and methods of the present invention and are therefore not to be considered limiting of the embodiments of products and methods of the present invention's scope as it may include other effective embodiments as well. Like numbers refer to like elements throughout. Further, numbers that have common ones and tens digits with different hundreds or thousands digits are intended to indicate similar elements in alternative embodiments.

In accordance with some embodiments described in this disclosure, it is advantageous to provide systems, articles of manufacture, and methods providing for one or more of the following features: (1) a mold (or form) that may be packed (e.g., by a user, by an automated machine process) with the desired amount and/or density of hydrophobic molding substance; (2) the combination of two or more molds to allow for larger, combination structures (e.g., structures comprising two or more levels or tiers of molded structures, such as a first tower structure placed atop one or more other tower structures); (3) a mold system comprising at least one mold having multiple sides connected by hinges (e.g., a living hinge) and/or by other securing means; (4) a mold system comprising a tamping tool, a mold, a securing member (e.g., a removable joining key), and/or a mold cap (e.g., a mold end cap) configured to fit in the mold for packing and/or shaping a moldable material in the mold; (5) a mold system comprising a mold having at least three sides, each side connected by a respective living hinge to at least one other side, and an integrated and/or removable mold cap for packing and/or shaping a moldable material against in the mold; and/or (6) a molding tool comprising a handle and a compactor portion, the molding tool further including at least one of the following features: (i) a scraper, (ii) a second compactor portion, and/or (iii) a grip.

Although various embodiments are described in this disclosure as being related to hydrophobic molding substances, it will be understood that various embodiments may be used with any molding substance, material, or composition, including but not limited to sand and snow, that may be suitable for forming desired structures (e.g., sand castle sculptures).

According to some embodiments a mold system is provided that includes two or more mold sections configured for use with one another to form a complete mold that is configured to form a structure or object dictated by the design of the combined mold sections (e.g., having a structure of desired shape, height, ornamental design, etc.). When the sections are combined or connected (e.g., to receive the hydrophobic molding substance) using one or more connection points, they may be packed with as much hydrophobic molding substance (e.g., sand, sand with water, snow, and/or other substance), as desired by the user for the intended purpose. According to some embodiments, two or more complete molds may be combined to create combination structures.

According to some embodiments, a mold section, a mold cap, and/or a removable mold form may comprise one or more tabs, handles, or protrusions for gripping the mold component when separating the mold component from the formed structure.

According to some embodiments, a mold system may comprise a first set of mold sections configured to be connected to one another to form a first complete mold, and a second set of mold sections configured to be connected to one another to form a second complete mold. The first complete mold and the second complete mold are further configured so that the second complete mold may be placed on top of the first complete mold to create a combination of both molds and/or for creating a combination structure. For example, a second complete mold may be formed (e.g., by attaching its multiple sections together) and fit in place on or otherwise combined with the first complete mold.

This combination of separate molds is not possible with traditional fill-and-flip or container-type molds (e.g., a traditional sand pail) in which sand, for example, is placed in a mold container having a solid, bottom container wall, and then the mold container is inverted to form a structure on a surface. There is no way to remove a first container-type mold after a second mold (of any type) is placed on top of it—the second structure would be built on top of the bottom container wall that is now the top surface of the inverted mold container.

In contrast to traditional fill-and-flip or container-type molds (e.g., a traditional sand pail) in which sand, for example, is placed in a mold container having a solid, bottom container wall, and then the mold container is inverted to form a structure on a surface, some embodiments of the present invention provide for mold systems having separable mold sections providing advantages over traditional, container-type molds. Various embodiments of mold systems are described in this disclosure such that when two or more mold sections are combined to form a complete mold, the complete mold has at least one exposed opening. For example, two mold sections may be combined to create a tower mold having a bottom opening that will be placed on the building surface (e.g., a beach surface, a worktable, etc.) with or without a mold cap covering the bottom opening, and an upper opening that may be used for filling the mold with the desired molding substance (e.g., a hydrophobic sand).

In accordance with some embodiments, a first complete mold may be configured to be joined with a second complete mold at the upper opening of the first complete mold. For example, a bottom opening of the second (upper) complete mold may be joined with the upper opening of the first (bottom) complete mold to create, effectively, a single combined mold that allows all the inserted hydrophobic molding substance to be packed together, which may allow for denser packing and/or stronger formed structures. Such a configuration also allows advantageously for molding of an upper portion of a combination structure by filling the second complete mold, while the first (bottom) complete mold is still in place. Alternatively, the first (bottom) complete mold may be configured to be removable before the upper portion is completed, as desired.

In either case, the upper portion is structurally integrated with the bottom portion of the combination structure by effectively packing additional hydrophobic molding substance directly on top of the hydrophobic molding substance at the top the first (bottom) complete mold, through the lower opening of the second (upper) complete mold that is joined with the upper opening of the first (bottom) complete mold. Once the upper structure portion is molded, the second complete mold may be removed. Finally, if not removed previously, the first (bottom) complete mold may be disassembled and separated from the bottom part of the structure, leaving a free-standing combination structure.

In one example, as described in this disclosure, a first complete mold may be formed of two halves of a first cylindrical mold that is not closed on the top, allowing for the creation of a first column structure with an exposed top surface (e.g., the bottom section of a sand castle tower). A second complete mold may then be used to form a second structure on top of the exposed top surface of the first column structure (e.g., an upper section of the example sand castle tower). As noted above, the second complete mold may be but need not necessarily be joined to the first complete mold.

In some embodiments, a split-mold system may comprise at least two sections that may be stably connected to one another, directly or indirectly, by one or more permanent connections (e.g., a living hinge) and may be stably but separably connected to one another using one or more types of slots or holes, with corresponding connective elements (e.g., a key-and-lock system, snap joints with corresponding male and female elements). In one embodiment, a plurality of mold sections are connected by respective hinges (e.g., a living hinge), and the entirety of the connected mold sections may be folded at the hinges and thus joined to form a closed mold, which may be further secured, for example, using a key and lock or other type of securing device to secure together the opposite ends of the plurality of connected mold sections.

In some embodiments, the two or more mold sections of the mold system are configured to be completely separable from one another and to be connected to one another (i.e., to be detachably connectable to one another) to form a complete mold. In some embodiments, a split-mold system may comprise two sections that may be stably connected to one another, directly or indirectly, by one or more permanent connections (e.g., a living hinge) and stably connected to one another using one or more types of slots or holes, with corresponding connective elements (e.g., a key-and-lock system, snap joints with corresponding male and female elements). In some embodiments, a split-mold system may comprise two sections that may be stably connected to one another using one or more types of slots or holes, with corresponding connective elements (e.g., a key-and-lock system, snap joints with corresponding male and female elements). In some embodiments, the split-mold system comprises two separable sections that may be more robustly secured to one another using, for example and without limitation, a latch, a snap joint, buckle, hook-and-eye closure, elastic bands, nut and bolt, a clip, a cotter pin, a clamp, or other securing system for securely connecting the sections to each other, to create a complete mold. A split-mold system is advantageous, in accordance with some embodiments, for making transportation and/or storage of the mold system easier than with traditional, single-piece molds. For instance, because each separable section is smaller than the complete mold it forms, it is easier to store the sections of a split-mold system individually, nested together, and/or stacked on one another for transportation and/or storage.

In some embodiments, the two or more mold sections of the mold system may be permanently attached to one another via at least one connection point (e.g., by a living hinge) and are configured to be detachably connectable to one another at another connection point (e.g., using one or more of the connecting and/or securing systems, as noted above).

In one or more embodiments, a point of connection, at which two mold sections are detachably connectable, may be further configured to receive or to be manipulated by a device for breaking a vacuum to facilitate separation of the mold from the formed structure.

According to some embodiments, a castle-mold system is provided that includes two or more sections that can be combined to form the molding shape, that can be packed with as much sand, water, snow (or other substance), as needed. A key and key opening system is provided to hold the mold sections in place and to create a mold.

In accordance with some embodiments of the present invention, an article of manufacture is provided comprising at least one compactor portion and/or at least one shaping tool (e.g., a scraper) for compacting, shaping, and/or removing molding substance of a formed structure. In one embodiment, a molding tool may comprise a plurality of compactor portions (e.g., of varying sizes and/or shapes) for compacting areas of a formed structure (e.g., to smooth and/or create detail designs) and/or for tamping moldable substance in a mold device to form a structure.

According to some embodiments, a kit for forming structures from a hydrophobic molding substance is provided, the kit comprising one or more of the following features: a joining key; a molding tool that may include a handle and at least one compactor portion; a mold cap; a first mold section defining a first shape, and comprising a first key opening for receiving the joining key; a second mold section defining a second shape, the second mold section being connected to the first mold section by a first living hinge; a third mold section defining a third shape, the third mold section being connected to the second mold section by a second living hinge; and a fourth mold section defining a fourth shape, the fourth mold section being connected to the third mold section by a third living hinge, the fourth mold section including: a second key opening for receiving the joining key, where the first mold section, the second mold section, the third mold section, and the fourth mold section are configured for forming a first mold assembly for receiving a hydrophobic molding compound by: folding adjacent mold sections toward each other using the respective living hinges, and securing the first mold section and the fourth mold section together by insertion of the joining key through the first key opening and through the second key opening, and where the mold cap is configured to be located abutting an end of the first mold assembly to form a second mold assembly.

According to some embodiments, a mold system for forming structures from a molding substance is provided, the kit comprising one or more of the following features: a joining key; a first mold section defining a first shape, and including a first key opening for receiving the joining key; and a second mold section defining a second shape, and including: a second key opening for receiving the joining key, where the first mold section and the second mold section are configured to be secured together to assemble a first mold device by insertion of the joining key through the first key opening and through the second key opening.

According to some embodiments, implementation of a mold system may further include one or more of the following features: a mold cap configured to be located abutting the first mold section and the second mold section when secured together to assemble a second mold device; where the joining key is configured with the first key opening and the second key opening such that when rotated to a locking position the joining key cannot be removed from the first key opening and the second key opening; where the joining key is configured with the first key opening and the second key opening such that when rotated to a removing position the joining key is removable from the first key opening and the second key opening; where the first mold device is configured for forming a structure defined by the first shape and the second shape; where at least one of the first mold section and the second mold section may include a removable mold form such that when a moldable substance is compacted in the first mold device to form the structure, removing the removable mold form creates a corresponding space in the resulting structure; where the second mold device is configured for forming a structure defined by the first shape, the second shape, and the mold cap; where the first mold device has a first opening and a second opening opposite the first opening, each of the first opening and the second opening allowing for inserting a molding substance into the first mold device; where the molding substance may include a hydrophobic molding compound suitable for producing fine detail in the first mold device; where the second mold device is configured with a first opening and the mold cap placed opposite the first opening, the first opening allowing for inserting a molding substance into the second mold device; a molding tool configured with at least one compactor portion for tamping a moldable substance in the first mold device; a molding tool may include one or more of: a handle, at least one compactor portion, a grip, and/or a scraper; a third mold section defining a third shape, where the third mold section is connected to the first mold section; where the third mold section further is connected to the second first mold section; a fourth mold section defining a fourth shape, where the third mold section is further connected to the fourth mold section, and where the fourth mold section is further connected to the second mold section; where the first mold section is connected to a third mold section, different from the second section, by a living hinge; and/or where the first mold section is connected to the second mold section, directly or indirectly, by at least one living hinge.

According to some embodiments, a kit for forming structures from a molding substance is provided, the kit comprising one or more of the following features: a first mold section defining a first shape; a second mold section defining a second shape; the first mold section may include a first joining component for joining the first mold section to a corresponding second joining component of the second mold section to form a complete mold for containing molding substance to form a structure defined by the first shape and the second shape, and the complete mold having an opening for filling the complete mold with a molding substance; a mold cap defining a third shape for modifying the complete mold; and/or a securing device for securing the first mold section to the second mold section when the first mold section is joined to the second mold section.

According to some embodiments, implementation of a kit may further include one or more of the following features: a molding tool may include a handle, at least one compactor portion, and/or a scraper; where the securing device may include a removable key; where each of the joining component of the first mold section and the joining component of the second mold section may include a respective opening for receiving the securing device; where the securing device may include one or more of the following: a latch, a hook-and-eye closure, a snap joint, elastic band, a cotter pin, a bolt and nut, a clamp, and a clip; where the first mold section is identical to the second mold section; where the first mold section is different from the second mold section; a third mold section defining a third shape, the third mold section may include a third joining component for joining the third mold section to at least one of the first joining component of the first mold section and the second joining component of the second mold section; and/or where the mold cap may include at least one flange.

According to some embodiments, a method for using a mold to form a structure using a moldable substance may include one or more of the following steps: forming a mold device from a first mold section defining a first shape and a second mold section defining a second shape by: joining a first joining component of the first mold section to a corresponding second joining component of the second mold section, and securing with a securing device the first mold section to the second mold section when the first mold section is joined to the second mold section, the mold device having a first opening and a second opening opposite the first opening; blocking the second opening; inserting a portion of a moldable substance through the first opening into an interior of the mold device; tamping, using a compacting tool, the inserted first portion of the moldable substance in the interior of the mold device to compact the inserted first portion; repeating the steps of inserting and tamping in the interior of the mold device to form a structure of the moldable substance; and releasing the securing device and disassembling the mold device from around the formed structure.

According to some embodiments, implementation of a process for forming a structure may further comprise one or more of the following features: where blocking the second opening may include: applying a mold cap to the mold device to block the second opening; inverting the mold device such that the mold cap is on the bottom of the mold device; after forming the structure of the moldable substance, positioning the mold device such that the mold cap is accessible; and/or removing the mold cap from the second opening.

In accordance with some embodiments, any kits or systems described in this disclosure may comprise one or more of:

• • a) a container (e.g., a bag or box) for storing and/or transporting the components of a mold system;
  • b) a mold;
  • c) a molding tool; and/or
  • d) a securing device.

B. Terms and Definitions

Throughout the description that follows and unless otherwise specified, the following terms may include and/or encompass the example meanings provided in this section. These terms and illustrative example meanings are provided to clarify the language selected to describe embodiments both in the specification and in the appended claims, and accordingly, are not intended to be limiting.

“Molding substance” refers to materials and/or compositions such as snow, sand (preferably but not necessarily mixed with water or other liquid), soil, clay, modeling compound, wax, and/or other materials, which may be molded or otherwise shaped to form structures, sculptures, and other objects (e.g., sand castles of beach sand, blocks of snow, wax figures). In some instances, molding substances may be compactible, such as sand or snow, and preferably are packed or pressed into a mold to form denser or stronger structures. To provide some illustrative and non-limiting examples, reference may be made in this disclosure to sand castles and sand castle structures (e.g., structures of sand that include and/or evoke features of castles, towers, walls, and the like). It will be readily understood, however, in light of this disclosure, that unless explicitly stated otherwise, no embodiment is intended to be limited to use for creating structures of sand or structures resembling castles.

C. Systems, Articles of Manufacture, and Methods

FIGS. 1-3 show examples of components of a mold system in accordance with some embodiments of the present invention. An example mold 100 of a mold system for a tower is depicted in FIG. 1, in accordance with one embodiment. The mold 100 comprises a plurality of mold sections 102a-d. Each mold section defines a corresponding mold shape 104a-d, respectively, such as a castle design or any other desired design. As depicted in FIG. 1, each mold section 102a-d is flexibly attached to at least one other mold section by one or more of the living hinges 106a-c. As depicted, mold section 102a is connected by living hinge 106a to mold section 102b, which is further connected to mold section 102c by living hinge 106b, which is further connected to mold section 102d by living hinge 106c.

In accordance with one embodiment, the mold 100 may be closed by rotating the mold sections 102a-d toward one another using the living hinges 106a-c, forming a mold device with at least one opening and having an interior into which moldable substance may be inserted (through one or more of the openings) to form a structure defined by the combination of mold shapes 104a-d.

In accordance with one or more embodiments, the example mold 100 further comprises a mold cap 116 which may be used (as shown for illustrative purposes) at one end of the mold 100. The example mold cap 116 includes a mold cap shape 118 that may be used for defining a formed structure. As discussed further with respect to FIGS. 6A-6F, the mold cap 116 may be used as the bottom of a formed mold device to shape what will be the top of a formed structure when the mold device is inverted before releasing the formed structure, while moldable substance is inserted into a top opening of the closed mold device.

In some embodiments, the mold 100 may be closed to form a mold device by joining components such as joining components 108 and 112. As depicted in FIG. 1, the joining component 108 at mold section 102a is configured to mate with joining component 110 at mold section 102d. The example joining components further comprise openings 110 and 114, respectively, for receiving a securing device (e.g., a joining key) to removably secure the mold sections 102a and 102d together to form a mold device that is stable enough to receive moldable substance that can even be compacted in the formed mold device (e.g., using a compacting tool or compacting portion of a molding tool).

FIG. 2 depicts an example mold 200 for an example wall similarly comprising four mold sections 202a-d. It will be readily understood that a mold system in accordance with some embodiments may comprise any number of two or more such mold sections. The example mold system further comprises joining components 208 and 212, each having a corresponding opening 210 and 214, respectively. A mold cap 216 includes a mold cap shape 218 for forming the top of the example wall when the mold 200 is closed, as described above.

FIG. 3 depicts an example mold 300 for an example keep structure similarly comprising four example mold sections connected by living hinges. The example mold system further comprises joining components 308 and 312, each having a corresponding opening 310 and 314, respectively. A mold cap 316 includes a mold cap shape 318 for forming the top of the example keep when the mold 300 is closed, as described above.

FIG. 4 depicts an example molding tool 400 in accordance with some embodiments of the present invention. The molding tool 400 preferably includes a handle 101 and at least one compactor portion or compacting tool 402, 404, and/or 410. It will be readily understood that any number, size, and/or shape of compactor portion may be included in a molding tool as desired for a particular implementation. The example compactor portion 402 may be used, for example, with larger openings in mold devices for tamping down moldable sand or other moldable substance when forming a structure (e.g., a sand castle feature); the smaller compactor portion 410 may be suitable for use with smaller or narrower openings (e.g., the opening formed by example mold 200 for a wall). The example compactor 404 may be useful in some implementations for shaping and/or compacting further formed structures. The molding tool 400 may further comprise one or more grips 406 enabling more secure handling by a user. The molding tool 400 may further comprise one or more other types of shaping tools, such as example scraper 408, for shaping and/or removing moldable substance to achieve a desired design.

FIG. 5 depicts an example joining key 500 in accordance with some embodiments of the present invention. Joining key 500 may comprise a handle 502, a shaft 504, and a flange 506 and may be utilized, as described in this disclosure for securing adjoined mold sections together to form a mold device. For example, joining key 500 may be suitable for inserting through both openings 114 and 110 of mold 100 in order to secure mold sections 102a and 102d together before inserting moldable substance in the formed mold device. In one embodiment, the joining key 500 may be configured such that the flange 506 and shaft 504 are insertable through a key opening in a first orientation (e.g., with the flange 506 substantially vertical). By rotating the key 500 so that the flange 506 cannot be withdrawn through the opening, the key 500 may be secured through the openings, securing the mold sections together until the key is rotated again and withdrawn (e.g., for releasing a mold device from a formed structure).

FIG. 6A depicts an example mold device 600 formed of a plurality of moldable sections, including mold sections 602a and 602d, and secured by a flange 632 of example key 630 being placed through an opening (not shown) of joining component 608 and through opening 614 of joining component 612. As depicted in FIG. 6A, mold section 602a defines a first shape 604a; mold section 602d defines a second shape 604d. A living hinge 606a connects mold section 602a to another mold section (not shown). Example mold cap 616 is depicted as blocking an opening in the formed mold device 600.

FIGS. 6B-6F depict an example use of the mold device 600 to create an example tower structure. As shown in FIG. 6B, a user may invert the mold device 600 so that the inserted mold cap 616 blocking one opening is on the bottom, and insert a portion of moldable substance 642 through opening 640 to begin forming a structure. As depicted in FIG. 6C, a molding tool 644 comprising a compactor portion (not shown) may be used to tamp down the inserted substance to the desired density. When, as depicted in FIG. 6D, the mold device 600 is filled with moldable substance 642, the mold device 600 may be inverted, as shown in FIG. 6E, or otherwise positioned so that mold cap 616 (defining a shape 618) may be accessed for removal. Finally, as shown in FIG. 6F, key 630 may be removed so that the mold device 600 may be split (e.g., by flexing its living hinges) to reveal the formed structure 650.

FIGS. 7A-7D depict example components of an example mold system. Example mold 700 for forming a gateway or archway comprises a space 702 for receiving a removable mold form 704. The removable mold form, as depicted in FIG. 7B, may comprise one or more protrusions or handles for removing the form from a closed mold device once a structure is formed. FIGS. 7C and 7D depicts different perspective views of the mold 700 with the removable mold form 704 installed.

Molds, molding tools, and mold devices may be of any desired size and/or shape. According to some embodiments, an example tower mold may be approximately 1¾″ wide by 3¼″ tall with removable cap intact; an example gatehouse mold may be approximately 3″ tall by 2⅛″ deep by 2⅜″ wide with removable cap intact; an example keep mold may be approximately 2″ tall by 3½″ deep by 2¾″ wide with removable top intact; an example wall mold may be approximately 2½″ tall by1¼″ deep by 4″ wide with removable cap intact; an example square tower mold may be approximately 2½″ tall by 2″ deep; an example small tower may be approximately 2⅜″ tall by 1½″ deep; and an example keep mold may be approximately 2″ tall by 3½″ deep with removable cap intact; an example molding tool may be approximately 5.5 inches long with the compactor portion of approximately 1 inch wide.

According to some embodiments, any one or more of the mold sections, mold systems, tools, and devices described in this disclosure may be formed from one or more materials (preferably waterproof materials), including but not limited to plastics, metals, alloys, ceramics, and/or other material having sufficient strength to carry out the purpose of this invention. In one example, mold sections of mold systems may be formed by injection molding of plastic material and/or any other technique.

Claims

1. A mold system for forming a structure from a hydrophobic molding compound, the mold system comprising:

a joining key;

a molding tool comprising a handle and at least one compactor portion;

a mold cap;

a first mold section defining a first shape, and comprising: a first key opening for receiving the joining key;

a second mold section defining a second shape, the second mold section being connected to the first mold section by a first living hinge;

a third mold section defining a third shape, the third mold section being connected to the second mold section by a second living hinge; and

a fourth mold section defining a fourth shape, the fourth mold section being connected to the third mold section by a third living hinge, the fourth mold section comprising: a second key opening for receiving the joining key,

wherein the first mold section, the second mold section, the third mold section, and the fourth mold section are configured for forming a first mold assembly for receiving a hydrophobic molding compound by: folding adjacent mold sections toward each other using the respective living hinges, and securing the first mold section and the fourth mold section together by insertion of the joining key through the first key opening and through the second key opening, and

wherein the mold cap is configured to be located abutting an end of the first mold assembly to form a second mold assembly.

2. A mold system for forming a structure from a molding substance, the mold system comprising:

a joining key;

a first mold section defining a first shape, and comprising: a first key opening for receiving the joining key; and

a second mold section defining a second shape, and comprising: a second key opening for receiving the joining key,

wherein the first mold section and the second mold section are configured to be secured together to assemble a first mold device by insertion of the joining key through the first key opening and through the second key opening.

3. The mold system of claim 2, further comprising:

a mold cap configured to be located abutting the first mold section and the second mold section when secured together to assemble a second mold device.

4. The mold system of claim 2, wherein the joining key is configured with the first key opening and the second key opening such that when rotated to a locking position the joining key cannot be removed from the first key opening and the second key opening.

5. The mold system of claim 2, wherein the joining key is configured with the first key opening and the second key opening such that when rotated to a removing position the joining key is removable from the first key opening and the second key opening.

6. The mold system of claim 2, wherein the first mold device is configured for forming a structure defined by the first shape and the second shape.

7. The mold system of claim 6, wherein at least one of the first mold section and the second mold section comprises a removable mold form such that when a moldable substance is compacted in the first mold device to form the structure, removing the removable mold form creates a corresponding space in the resulting structure.

8. The mold system of claim 2, wherein the second mold device is configured for forming a structure defined by the first shape, the second shape, and the mold cap.

9. The mold system of claim 2, wherein the first mold device has a first opening and a second opening opposite the first opening, each of the first opening and the second opening allowing for inserting a molding substance into the first mold device.

10. The mold system of claim 9, wherein the molding substance comprises a hydrophobic molding compound suitable for producing fine detail in the first mold device.

11. The mold system of claim 2, wherein the second mold device is configured with a first opening and the mold cap placed opposite the first opening, the first opening allowing for inserting a molding substance into the second mold device.

12. The mold system of claim 2, further comprising:

a molding tool configured with at least one compactor portion for tamping a moldable substance in the first mold device.

13. The mold system of claim 12, further comprising:

a molding tool comprising: a handle, and a first compactor portion.

14. The mold system of claim 13, the molding tool further comprising at least one of the following:

a grip,

a scraper, and

a second compactor portion.

15. The mold system of claim 2, further comprising:

a molding tool comprising: a handle, a first compactor portion, a second compactor portion, a third compactor portion, a grip, and a scraper.

16. The mold system of claim 2, further comprising:

a third mold section defining a third shape, wherein the third mold section is connected to the first mold section.

17. The mold system of claim 16, wherein the third mold section further is connected to the second first mold section.

18. The mold system of claim 16, further comprising:

a fourth mold section defining a fourth shape,

wherein the third mold section is further connected to the fourth mold section, and

wherein the fourth mold section is further connected to the second mold section.

19. The mold system of claim 2, wherein the first mold section is connected to a third mold section, different from the second section, by a living hinge.

20. The mold system of claim 2, wherein the first mold section is connected to the second mold section, directly or indirectly, by at least one living hinge.

21. A kit for forming structures from molding substances, the kit comprising:

a first mold section defining a first shape;

a second mold section defining a second shape; the first mold section comprising a first joining component for joining the first mold section to a corresponding second joining component of the second mold section to form a complete mold for containing molding substance to form a structure defined by the first shape and the second shape, and the complete mold having an opening for filling the complete mold with a molding substance;

a mold cap defining a third shape for modifying the complete mold; and

a securing device for securing the first mold section to the second mold section when the first mold section is joined to the second mold section.

22. The kit of claim 21, further comprising a molding tool comprising a handle and at least one compactor portion.

23. The kit of claim 21, further comprising a molding tool comprising a handle, a first compactor portion, a second compactor portion, and a scraper.

24. The kit of claim 21, wherein the securing device comprises a removable key.

25. The kit of claim 21, wherein each of the joining component of the first mold section and the joining component of the second mold section comprises a respective opening for receiving the securing device.

26. The kit of claim 21, wherein the securing device comprises one or more of the following:

a latch,

a hook-and-eye closure,

a snap joint,

elastic band,

a cotter pin,

a bolt and nut,

a clamp, and

a clip.

27. The kit of claim 21, wherein the first mold section is identical to the second mold section.

28. The kit of claim 21, wherein the first mold section is different from the second mold section.

29. The kit of claim 21, further comprising:

a third mold section defining a third shape,

the third mold section comprising a third joining component for joining the third mold section to at least one of the first joining component of the first mold section and the second joining component of the second mold section.

30. The kit of claim 21, wherein the mold cap comprises at least one flange.

31. A method for using a mold to form a structure using a moldable substance, the method comprising:

forming a mold device from a first mold section defining a first shape and a second mold section defining a second shape by: joining a first joining component of the first mold section to a corresponding second joining component of the second mold section, and securing with a securing device the first mold section to the second mold section when the first mold section is joined to the second mold section, the mold device having a first opening and a second opening opposite the first opening;

blocking the second opening;

inserting a portion of a moldable substance through the first opening into an interior of the mold device;

tamping, using a compacting tool, the inserted first portion of the moldable substance in the interior of the mold device to compact the inserted first portion;

repeating the steps of inserting and tamping in the interior of the mold device to form a structure of the moldable substance; and

releasing the securing device and disassembling the mold device from around the formed structure.

32. The method of claim 31, wherein blocking the second opening comprises:

applying a mold cap to the mold device to block the second opening.

33. The method of claim 32, further comprising: inverting the mold device such that the mold cap is on the bottom of the mold device.

34. The method of claim 32, further comprising:

after forming the structure of the moldable substance, positioning the mold device such that the mold cap is accessible; and

removing the mold cap from the second opening.