Curved Concrete Mold Kit Using Segmented Arc Pieces

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Solution Overview

Problem

The tilt-up construction technique is limited by the inability to create concrete elements with non-polygonal contours, as existing mold formation methods restrict the creation of curved shapes.

Innovation Solution

A kit comprising mold pieces shaped as circular arcs with dovetail joints for interlocking, allowing the assembly of molds for casting concrete elements with various radii and angles, enabling the creation of both partially curved top, bottom, and side contours.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional lumber beams and aluminum extruded beams are used to form molds, then the construction process is simple and cost-effective, but the concrete elements are limited to polygonal contours only

Engineering Contradiction:

Improvecontour shape of concrete elementsVSAvoidmold structure complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The mold is divided into multiple individual mold pieces, each shaped as a circular arc segment. These segments can be assembled in different combinations to create various curved contours, replacing the traditional single-piece polygonal mold structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mold pieces are specifically shaped with circular arc geometries having different radii (30 inches, 60 inches, 90 inches). This curvature design enables the creation of rounded and curved concrete element contours that were previously impossible with straight-beam traditional molds.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Adaptability or versatility

If custom molds are designed for each curved shape, then unique curved contours can be achieved, but the cost and time for mold fabrication increase significantly

Engineering Contradiction:

Improvevariety of curved shapesVSAvoidmold fabrication ease

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A universal set of standardized mold pieces with specific circular arc radii (30, 60, 90 inches) and 45-degree arc angles can be used to create multiple different curved shapes. By varying the number and arrangement of these standard pieces, various curved contours can be achieved without fabricating custom molds for each design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The mold configuration can be adjusted by changing parameters such as the number of mold pieces, their arrangement sequence, and the selection of different radii. This allows the same set of standardized pieces to produce different curved shapes, providing design flexibility without requiring custom fabrication.

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If more mold pieces with different radii are included in the kit, then more diverse curved shapes can be created, but the kit complexity and storage requirements increase

Engineering Contradiction:

Improvediversity of curved element shapesVSAvoidnumber of mold pieces in kit

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The mold system is segmented into discrete, standardized pieces that can be selectively assembled. This segmentation allows users to choose only the pieces needed for a specific project, reducing the number of pieces that must be stored and handled while maintaining the ability to create diverse shapes.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11426897B2Kits suitable for casting concrete elements, and methods for casting concrete elements using such kits

Publication Date: 2022.08.30 POWERS BROWN ARCHITECTURE HLDG

AI summary

Buildings are constructed using the tilt-up technique from concrete elements that have contours that are at least partially curved. The concrete elements are made by casting in molds. The molds are assembled from mold pieces selected in a kit that contains a limited set of shapes. Molds assembled differently can produce concrete elements with a large variety of contour shapes.