Mold for Making Units of a Dome Structure and Method of Using the Same
20170136653 ยท 2017-05-18
Inventors
Cpc classification
E04B1/3211
FIXED CONSTRUCTIONS
B29C45/40
PERFORMING OPERATIONS; TRANSPORTING
B28B7/0029
PERFORMING OPERATIONS; TRANSPORTING
B29C33/302
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/10
PERFORMING OPERATIONS; TRANSPORTING
A63H33/14
HUMAN NECESSITIES
E04B2001/327
FIXED CONSTRUCTIONS
International classification
B29C45/40
PERFORMING OPERATIONS; TRANSPORTING
B29C33/30
PERFORMING OPERATIONS; TRANSPORTING
E04B1/32
FIXED CONSTRUCTIONS
Abstract
Described herein is a mold for making units of a dome structure, comprising: a first mold piece, a second mold piece, a third mold piece; the third mold piece is configured to be sandwiched between and assembled with the first and second mold pieces; wherein an assembly of the first mold piece, the second mold piece, and the third mold piece is configured to form a mold cavity; wherein the third mold piece comprises a plurality of sidewall plates; wherein the plurality of sidewall plates are perpendicular to a same spherical surface when the third mold piece is assembled with the first and second mold pieces. Described herein is also a method of using the mold, and the method comprises: assembling the plurality of sidewall plates to form the third mold piece; assembling the second mold piece and the third mold piece; assembling the first mold piece with the second mold piece and the third mold piece to form the mold cavity of a first-level mold; injecting a molding material into the mold cavity; forming a unit of a first-level dome structure by allowing the molding material to form into shape; opening the first-level mold; extracting the unit of the first-level dome structure.
Claims
1. A mold for making units of a dome structure, comprising: a first mold piece, a second mold piece, a third mold piece; wherein the third mold piece is configured to be sandwiched between and assembled with the first and second mold pieces; wherein an assembly of the first mold piece, the second mold piece, and the third mold piece is configured to form a mold cavity; wherein the third mold piece comprises a plurality of sidewall plates; wherein the plurality of sidewall plates are perpendicular to a same spherical surface when the third mold piece is assembled with the first and second mold pieces.
2. The mold of claim 1, wherein the first mold piece comprises a first spherical surface.
3. The mold of claim 2, wherein each of the plurality of sidewall plates comprises an end surface conforming to the first spherical surface.
4. The mold of claim 1, wherein the second mold piece comprises a second spherical surface.
5. The mold of claim 4, wherein each of the plurality of sidewall plates comprises an end surface conforming to the second spherical surface.
6. The mold of claim 1, wherein a cross section of the mold cavity is an equilateral triangle in shape.
7. The mold of claim 1, wherein a cross section of the mold cavity is a triangle in shape.
8. The mold of claim 1, wherein a cross section of the mold cavity is isosceles trapezoid in shape.
9. The mold of claim 1, wherein the third mold piece comprises three or more sidewall plates.
10. The mold of claim 1, further comprising a plurality of fasteners configured to join the plurality of sidewall plates with each other.
11. The mold of claim 1, further comprising a plurality of fasteners configured to join the plurality of sidewall plates with the first mold piece or second mold piece to form the mold cavity.
12. The mold of claim 1, wherein the plurality of sidewall plates comprise a plurality of through holes.
13. The mold of claim 1, wherein the second mold piece comprises a plurality positioning holes for joining with the third mold piece.
14. The mold of claim 13, wherein the plurality positioning holes comprises a first group of four positioning holes that are on a first minor arc of a first great circle of the second spherical surface.
15. The mold of claim 14, wherein the plurality positioning holes comprises a second group of two positioning holes that are on a second minor arc of a second great circle of the second spherical surface.
16. The mold of claim 1, further comprising a base that is configured to support an assembly of the first, second and third mold piece.
17. The mold of claim 1, wherein the mold cavity is configured for receiving a molding material for making units of the dome structure.
18. The mold of claim 1, further comprising an injection hole for receiving a molding material into the mold cavity.
19. A method of using the mold of claim 1, wherein the method comprising: assembling the plurality of sidewall plates to form the third mold piece; assembling the second mold piece and the third mold piece; assembling the first mold piece with the second mold piece and the third mold piece to form the mold cavity of a first-level mold; injecting a molding material into the mold cavity; forming a unit of a first-level dome structure by allowing the molding material to form into shape; opening the first-level mold; extracting the unit of the first-level dome structure.
20. A method of making units of a dome structure using a set of molds, wherein each set of molds are configured for making units of the dome structure; wherein the set of molds comprises a first-level mold; wherein the first-level mold comprises a first mold piece, a second mold piece, and a third mold piece; wherein the third mold piece is configured to be sandwiched between and assembled with the first and second mold pieces; wherein the third mold piece comprises a plurality of sidewall plates; wherein the plurality of sidewall plates are perpendicular to a same spherical surface when the third mold piece is assembled with the first and second mold pieces; wherein the first-level mold comprises an injection hole for receiving a molding material into the mold cavity; the method comprising: assembling the plurality of sidewall plates to form the third mold piece; assembling the second mold piece and the third mold piece; assembling the first mold piece with the second mold piece and the third mold piece to form the mold cavity of the first-level mold; injecting the molding material into the mold cavity; forming a unit of a first-level dome structure by allowing the molding material to form into shape; opening the first-level mold; extracting the unit of a first-level dome structure.
Description
BRIEF DESCRIPTION OF FIGURES
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DETAILED DESCRIPTION
[0042] According to an embodiment, a mold for making units of a dome structure comprises a first mold piece 10, a second mold piece 20, and a third mold piece 30. According to an embodiment as shown in
[0043] According to an embodiment, the first spherical surface is part of a sphere with a radius of r. Preferably, the sphere with radius r may conform with the inner hemisphere of the dome structure.
[0044] According to an embodiment, the second spherical surface is part of a sphere with a radius of R. Preferably, the sphere with radius R may conform with the outer hemisphere of the dome structure.
[0045] According to an embodiment, r is smaller than R in value.
[0046] According to an embodiment as shown in
[0047] As shown in
[0048] As shown in
[0049] According to an embodiment, when the plurality of sidewall plates 301, 302, and 303 are the same in size, a cross section of the mold cavity 300 is an equilateral triangle in shape. Alternatively, sidewall plates 301 and 302 may be the same in size and 303 may be different in size from 301 and 302, such that a cross section of the mold cavity 300 may be an isosceles triangle in shape.
[0050] As shown in
[0051] As shown in
[0052] One embodiment of a sidewall plate 301 that may be used in
[0053] According to an embodiment, plurality of sidewall plates may comprise a plurality of through holes on the ends of the sidewall plates, which may be configured for receiving fasteners. As shown in
[0054] According to an embodiment of the mold, the mold further comprises a plurality of fasteners configured to join the plurality of sidewall plates with each other. As shown in
[0055] According to an embodiment as shown in
[0056] According to an embodiment as shown in
[0057] As shown in
[0058] According to an embodiment, positioning holes A1, B1, A2, B2, An, Bn, C1, D1, C2, D2, Cn and Dn may comprise internal threads. Such internal threads may mate with a respectively complementary thread of the screws S or other type of screws. Furthermore, optionally, when not in use, some of the positioning holes A1, B1, A2, B2, An, Bn, C1, D1, C2, D2, Cn and Dn may receive a screw T as shown in
[0059] According to an embodiment, the mold may optionally further comprises a base that is configured to support an assembly of the first, second and third mold piece. An embodiment of a base may be a column shaped base shown in
[0060] In alternative embodiments, the base of the mold may not need to be a separate piece. Rather the second mold piece may have its own support portion built to the bottom thereof. The support portion may be a foot, a leveled base, or a stand etc.
[0061] According to an embodiment as shown in
[0062] Described herein also is a method of making units of a dome structure using a set of molds, wherein each set of molds are configured for making units of the dome structure; wherein the set of molds comprises a first-level mold; wherein the first-level mold comprises a first mold piece, a second mold piece, and a third mold piece; wherein the third mold piece is configured to be sandwiched between and assembled with the first and second mold pieces; wherein the third mold piece comprises a plurality of sidewall plates; wherein the plurality of sidewall plates are perpendicular to a same spherical surface when the third mold piece is assembled with the first and second mold pieces; wherein the first-level mold comprises an injection hole for receiving a molding material into the mold cavity; wherein the method comprising: assembling the plurality of sidewall plates to form the third mold piece; assembling the second mold piece and the third mold piece; assembling the first mold piece with the second mold piece and the third mold piece to form the mold cavity of the first-level mold; injecting the molding material into the mold cavity; forming a unit of a first-level dome structure by allowing the molding material to form into shape; opening the first-level mold; extracting the unit of a first-level dome structure.
[0063] When the dome structure to be made has n number of levels, the set of molds comprise n number of level-specific third mold piece for making units for the n number of levels. Such units may be spherical triangular units, and an example of a dome structure assembled from plurality of level specific spherical triangular units is shown in
[0064] The assembled dome structure may also comprise skylights at the top of the dome. The assembled dome structure may further comprise windows and entryways when it's to be used as shelters or buildings. Windows or entryway may be designed within special purpose units of the dome structure.
[0065] According to an embodiment, units of different levels of a dome structure share common characteristics, that is, the units for a dome structure share the same internal radius and external radius of the dome structure. Therefore different levels of units are made from molds sharing the same first mold piece and second mold piece.
[0066] As described herein, units of a dome structure have sizes that are level specific. In general, a lower level unit is generally larger in its dimension than an upper level unit. The units may be made using molds that are level specific or have level specific component such as level specific third mold piece. According to an embodiment, even on the same level of a dome structure as shown in
[0067] A dome structure may have the benefit of lower consumption of construction materials, lower cost, higher enclosed space for use, higher structural strength and better safety. However, constructing a dome structure is difficult. Molds for pre-fabricated units of a dome structure solve the difficulty in constructing a dome bearing the perfect structural resemblance to a hemisphere. Units for dome structure may provide a wide range of applications in fields such as emergency shelters, building constructions or toys.
[0068] Molding material for the units of a dome structure may be selected based on the desired field of applications of the dome structure. According to an embodiment, a mold cavity is configured for receiving a molding material for making units of the dome structure. For example, when an application of the mold is in the field of toys, molding material may be a malleable substance used in building and sculpting, such as a type of rubber, a modelling clay that may comprise a ceramic clay, an oil-based clay such as plasticine, polymer clay polymer clay such as Fimo, Kato Polyclay, Sculpey, and Modello, plastics, paper clay, fibers or a combination thereof. Units made from such molding materials are to be used for purpose of education, training and exercise, or fun activity. Units made as such may be easily assembled by various means such as by using hot glue or double-sided tape.
[0069] In another example, when an application of the mold is in the field of making emergency shelters, molding material may be ice and snow, and the dome structure made is an igloo type structure. Units made from ice or snow may be assembled by stacking and filling the joining seams with snow.
[0070] In addition, when an application of the mold is in the field of industrial construction, molding material may be more durable materials such as metal, wood, foam material, plastics, cement, concrete, glass fiber, carbon fiber, or a combination thereof. The dome structure made thereof will be a more permanent type building. Units may be assembled according to industrial standard. It's also conceived that units may be joined furthermore by frames prefabricated for a dome structure.
[0071] According to an embodiment, the mold further comprises an injection hole for receiving a molding material into the mold cavity. An injection hole may be provided on any one of the first, second or third mold piece or on an additional part of the mold assembly.
[0072] According to an embodiment, the mold may be made of a variety type of materials, such as metal, wood, plastics, PVC, glass, foam material, carbon fiber etc. Preferably, the mold is made of low cost, durable and light weight material, for easy carry, use.
[0073] Although the mold described herein is provided as comprising a first, second and third mold piece, it is conceivable to one of ordinary skill in the art that the components may be combined or integrated into less number of pieces, or designed as more number of pieces, and all of which may still provide the same or similar functions as illustrated in the specification.
[0074] In relation to the claims, it is intended that when words such as a, an, at least one, or at least one portion are used to preface a feature there is no intention to limit the claim to only one such feature unless specifically stated to the contrary in the claim.
[0075] The descriptions above are intended to be illustrative, not limiting. Other embodiments, uses and advantages of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification should be considered exemplary only, and the scope of the invention is accordingly intended to be limited only by the following claims.