Abstract:
The concepts disclosed herein provide for a concrete mold that improves upon existing concrete molds known in the art. The hinged side-panel members that are locked to a hold-down frame allow for the mold to cure a concrete member, and then allow the concrete member to be removed without the need to break-down the frame surrounding the concrete member. During the pouring and ensuing curing process of the concrete member, the hinged side-panel members are secured to the hold-down frame and to each other in order to hold the concrete in the mold. Once the concrete is cured, the hinged side-panel members may be unlocked and opened quickly, allowing for expedient removal of the concrete member. After closing and re-locking the hinged side-panel members, the mold may be reused to cure another concrete member without the need to rebuild the frame around the mold.

Description:
PRIORITY CLAIM 
       [0001]    This application claims priority to U.S. Provisional Application No. 61/325,439, which is entitled “Hinged Mold for Pre-Formed Concrete Elements” and was filed on Apr. 19, 2010, the entire disclosure of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present inventions relate to apparatuses and methods for fabricating pre-formed concrete elements, and more particularly to forms used in making pre-formed concrete elements. 
         [0003]    Pre-formed concrete elements are widely used in building and industrial construction. For instance, pre-formed walls may be manufactured off-site and then shipped to a building site to be erected in the building construction. Other pre-formed elements include support walls, retention or barrier walls, and ground panels. The use of pre-formed concrete elements avoids uncertainties of pouring concrete at a jobsite, such as weather and temperature. Producing pre-formed elements off-site also allows for improved quality control. 
         [0004]    Improvements in fabrication of pre-formed concrete elements are always desired, especially improvements that can reduce material usage and improve fabrication speed. Current forms used to shape pre-formed concrete elements typically include wooden frames that are nailed or screwed together. After a concrete element has set, these frames are broken apart to release the concrete element. Creating the form, breaking it apart and recreating the form is a time consuming process. Additionally, the mechanical wear on the frame members means that they must be replaced frequently, increasing the monetary cost of the process as well. It is therefore desirable to have concrete forms that allow for faster fabrication of pre-formed concrete elements while increasing the useable lifespan of the concrete forms. 
       SUMMARY 
       [0005]    In accordance with one embodiment of the disclosure, there is provided a mold, comprising a casting bed, a liner configured to rest on a surface of the casting bed, a frame configured to rest on a surface of the liner opposite the surface of the casting bed, and a form attached to a surface of the frame opposite the surface of the liner. The form comprises a plurality of side-panel members, and each side-panel member includes ends which are complimentarily configured to fit together to create a closed perimeter. The plurality of side-panel members are in a closed position when the ends of each of the plurality of side-panels are engaged to create the closed perimeter. 
         [0006]    At least one of the plurality of side-panel members includes at least one hinge that connects the side-panel member to the frame. The frame includes hinge eyelets and the hinge includes longitudinal openings. The hinge eyelets and the longitudinal openings are simultaneously engaged by a connector which allows the side-panel member to rotate about the connector relative to the frame. The hinged side-panels are in an open position when the side-panel members have been rotated about the connector and the ends of each of the side-panels are no longer engaged to create the closed perimeter. 
         [0007]    At least one of the plurality of side-panel members includes at least one hold-down collar and the frame includes at least one corresponding hold-down pin. The hold-down collar is configured to engage the hold-down pin when the plurality of side-panels are in the closed position, and to disengage the hold-down pin to allow the side-panel members to be rotated to the open position. In some alternative embodiments, more than one of the plurality of side-panel members includes at least one hinge and at least one hold-down collar. 
         [0008]    In accordance with another embodiment of the disclosure, the frame comprises at least one hold-down member, or in alternative embodiments, at least two hold-down members. Each of the hold-down members includes chamfered edges configured to enable the at least two hold-down members to fit together. 
         [0009]    In accordance with another embodiment of the disclosure, there is provided a method comprising fastening a liner to a casting bed, fastening a frame to the liner, attaching a plurality of side-panel members to the frame (the side-panel members having ends which are configured to fit complimentarily together), engaging the ends of each of the side-panel members to form a closed perimeter, pouring a moldable material in the closed perimeter, allowing the moldable material to set, disengaging the ends of the side-panel members to create an opening in the perimeter, and removing the moldable material from the perimeter. 
         [0010]    In an alternative embodiment, disengaging the ends of the side-panel members further comprises rotating the side-panel members about a hinge connected to the frame. In another alternative embodiment, removing the moldable material from the perimeter further comprises applying leverage on the moldable material through the opening in the perimeter. 
         [0011]    In alternative embodiments, engaging the ends of each of the side-panel members to form a closed perimeter further comprises engaging hold-down pins on the frame with hold-down collars on the side-panel members to prevent disengaging of the ends of the side-panel members. Disengaging the ends of the side-panel members to create an opening in the perimeter further comprises disengaging hold-down pins from the hold-down collars to allow disengaging of the ends of the side-panel members. Disengaging the ends of the side-panel members to create an opening in the perimeter also further comprises rotating the side-panel members about a hinge connected to the frame and to the side-panel members. Removing the moldable material from the perimeter further comprises applying leverage on the moldable material through the opening in the perimeter. 
         [0012]    In yet another alternative embodiment, fastening the frame to the liner further comprises fitting together frame elements which have chamfered corners. 
         [0013]    The above described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and accompanying drawings. While it would be desirable to provide a pre-form mold that provides one or more of these or other advantageous features, the teachings disclosed herein extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned advantages. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0014]      FIG. 1  is an exploded view of a pre-form mold incorporating a hold-down frame and hinged side-panel members according to a disclosed embodiment; 
           [0015]      FIG. 2  is a plan view of a pre-form mold with hinged side-panels on four sides in a closed position, according to a further disclosed embodiment; 
           [0016]      FIGS. 3A-3F  are side views of hinged side-panel members of the mold shown in  FIG. 1 ; 
           [0017]      FIG. 4  is a perspective view of the pre-form mold of  FIG. 1  with the hinged side-panel members in an open position; 
           [0018]      FIG. 5  is a perspective view of the pre-form mold of  FIG. 1  with the hinged side-panel members in a closed position; 
           [0019]      FIG. 6  is a perspective view of the pre-form mold of  FIG. 1  with the hinged side-panel members in a closed position and concrete poured into the mold; and 
           [0020]      FIG. 7  is a perspective view of the pre-form mold of  FIG. 1  with the hinged side-panel members in an open position and a finished concrete element removed from the mold; and 
           [0021]      FIG. 8  is an exploded view of a hinge like that used in  FIGS. 1-7 . 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
         [0023]    An improved mold  100  for forming concrete elements is depicted in  FIG. 1 . The mold  100  may be configured to produce pre-cast panels, such as for use in retention, barrier or sound absorption walls. As used herein, the term “concrete” may include any cementitious mixture that is poured into a mold for curing. This includes concretes using any of a variety of aggregate materials, as well as cements. It is further contemplated that the mold  100  may be used with other moldable materials, such as moldable polymers or polymer composites. 
         [0024]    Mold  100  includes a casting bed  104  that provides a stable and level foundation to support the mold  100  and the concrete during the setting and curing process. Casting bed  104  may be primarily composed of one or more plywood sheets. Form liner  108  is set above casting bed  104 . Concrete poured into mold  100  rests on form liner  108  during the setting process. Form liner  108  may include a variety of shapes, patterns or contours in its surface that are transferred into the surface of the hardened concrete. Form liner  108  primarily consists of a material that is easily separated from the cured concrete. Plastic liners, for example, are commonly used for this purpose. 
         [0025]    Mold  100  further includes a hold-down frame assembled above form liner  108 . The hold-down frame shown in  FIG. 1  includes hold-down members  112 A,  112 B, and  112 C. The hold-down members  112 A-C each have chamfered corners that allow the hold-down members  112 A-C to fit together as seen at hold-down member joint  124 . While the corners seen in  FIG. 1  have a chamfered shape, alternative embodiments of hold-down members may employ squared corners. Additionally, alternative embodiments may employ a hold-down frame made of more or less than three separate hold-down members. For example, one alternative embodiment may employ a single-piece hold-down frame rather than a hold-down frame made of separate hold-down members  112 A-C. 
         [0026]    Hold-down members  112 A-C are locked together as shown in  FIG. 1 , and are secured to casting bed  104  with screws, bolts or other fasteners (not shown) extending through a plurality of mounting holes exemplified by mounting hole  113 . The hold-down frame additionally secures form liner  108  to the casting bed  104 . 
         [0027]    Side-panel members  116 A,  116 B, and  116 C are secured above the hold-down frame. As shown in  FIG. 1 , side-panel members  116 A-C are mounted atop hold-down frame members  112 A-C, respectively. Side-panel members  116 A-C hold concrete in place during the curing process, and may have a contoured interior shape, as shown by side-panel member  116 C. For instance, side-panel member  116 C has a rail contour in its interior surface which will form a groove in the side of the cured concrete. The contoured interior shape imparts a contoured edge to the concrete shaped in the mold  100 . 
         [0028]    The main body of each side-panel member  116 A-C is primarily composed of a material that is easily separated from cured concrete, such as wood. The exemplary side-panel members  116 A-C fit together with chamfered edges as seen at side-panel member joint  128 . The chamfering provides a secure seal at side-panel member joints  128  to contain concrete poured in the mold  100 . In alternative embodiments, side-panel member joints  128  may include perpendicular edges or any other configuration which provides a secure seal at side-panel member joints  128 . In another alternative embodiment, alternative joint shapes and structures such as gaskets or elastic seals may be used to seal side-panel member joints  128 . 
         [0029]    Side-panel members  116 A and  116 B each include at least one hinge member  120 . One embodiment of a hinge member  120 , which will be discussed below in more detail, is shown in  FIG. 8 . Hinge members  120  include longitudinal openings  125  positioned to correspond with hinge eyelets  121  on the hold-down members  112 A and  112 B. Some of the hinge members  120  also include hold-down collars  122 . Hold-down collars  122  are positioned to engage corresponding hold-down posts  123  on the hold-down members  112 A and  112 B. 
         [0030]      FIG. 1  and  FIG. 4  depict a concrete mold  100  having four sides and three side-panel members  116 A-C, with adjoining side-panel members  116 A and  116 B being configured with hinge members  120 , and side-panel  116 C not hinged, but secured to hold-down member  112 C; however, alternative embodiments are also envisioned. For example, as shown in  FIG. 2 , alternative side-panel member configurations may include hinged side-panel members  116 A′,  116 B′,  116 C′ and  116 D′, hold-down collars  122  and hold-down posts  123  on all four sides of a concrete mold  100 . In yet another alternative embodiment, the side-panel members  116 A-C having hinge members  120  may be placed on opposing sides of the concrete mold  100 . In other alternative embodiments, concrete molds  100  may have shapes with more or fewer than four sides employing side-panel members  116  with hinge members  120  on some or all of the sides of the mold  100 . 
         [0031]      FIGS. 3A-3F  depict cross-sectional views of side-panel members.  FIGS. 3A-3C  show the cross-sectional views of side-panel members  116 A and  116 B, for example.  FIG. 3A  depicts a section of the side-panel member  116 A/B which includes a longitudinal opening  125  and a hold-down collar  122  on a hinge member  120  like that shown in the embodiment of  FIG. 8 , for example. As described above, the hold-down collars  122  engage with hold-down posts  123  on hold-down members  112 A-C and longitudinal openings  125  correspond to hinge eyelets  121 . The cross-section of  FIG. 3A  depicts a portion of side-panel member  116 A/B which rotates about longitudinal opening  125  and may be locked in place with hold-down collar  122 .  FIG. 3B  depicts a section of the side-panel member  116 A/B which includes a longitudinal opening  125  on a hinge member  120  but no hold-down collar  122  so that the side-panel member  116 A/B rotates about longitudinal opening  125  but is not locked into place.  FIG. 3C  depicts a section of the side-panel member  116 A/B which does not include a hinge member  120 . Together,  FIGS. 3A-C  depict the different cross-sections of side-panel member  116 A/B and illustrate how the entire side-panel member  116 A/B is able to rotate and lock in place utilizing hinge members  120  that can rotate and be locked in place with hinge members  120  that only rotate. 
         [0032]      FIGS. 3D-F  show cross-sectional views of side-panel members  116 C′ and  116 D′. As described above and shown in  FIG. 2 , side-panel members  116 C′ and  116 D′ are hinged and include hold-down collars  122  and longitudinal openings  125 . Together,  FIGS. 3D-3F  depict the different cross-sections of side panel member  116 C′/D′ and illustrate how the entire side-panel member  116 C′/D′ is able to rotate and lock in place utilizing hinge members  120  that can rotate and be locked in place with hinge members  120  that only rotate. 
         [0033]      FIGS. 3A-3F  also illustrate how side-panel members  116 A and  116 B fit together with side-panel members  116 C or  116 C′ and  116 D′. The cross-sections of side-panel members  116 A and  116 B are thinner on the side that contacts the hold-down members  112 . Conversely, the cross-sections of side-panel members  116 C or  116 C′/D′ are thicker on the side that contacts the hold-down members  112 . The inverse shapes of side-panel members  116 A/B and  116 C or  116 C′/D′ are complementary and allow the side-panel members to form secure seals at side-panel joints between side-panel members  116 A/B and  116 C or  116 C′/D′. 
         [0034]      FIG. 4  depicts the concrete mold  100  of  FIG. 1  in an assembled configuration. The side-panel members  116 A and  116 B are joined to hold-down members  112 A and  112 B, respectively, with hinge members  120 . Each hinge member  120  includes a hinge cotter pin (not shown) that simultaneously engages the longitudinal openings  125  of the hinge members  120  of the side-panel members  116 A and  116 B and the hinge eyelets  121  of the hold-down members  112 A and  112 B. The hinge members  120  are pivoted at the outside of the hold-down members  112 A-C. Thus, when the hold-down members  112 A-C are fixed to the casting bed  104  (as shown in  FIG. 4 ), the side-panel members  116 A and  116 B may be rotated around the hinge cotter pin relative to the hold-down members  112 A and  112 B. It can be appreciated that connector elements other than a cotter pin may be used at the hinge members  120 . However, a cotter pin is beneficial because it can be readily removed to disassemble the side-panel members  116 A-C if desired. 
         [0035]    When the hold-down frame is assembled, as depicted in  FIG. 4 , the inner faces  114  of the hold-down members  112 A-C are oriented toward the center of form liner  108 . Conversely, the outer faces  115  of the hold-down members  112 A-C are oriented away from the center of the form liner  108 . In the open position depicted in  FIG. 4 , the side-panel members  116 A and  116 B are rotated about the hinge cotter pin of each hinge member  120 . Relative to the hold-down members  112 A and  112 B, the side-panel members  116 A and  116 B are rotated away from the inner faces  114  and toward the outer faces  115 . 
         [0036]      FIG. 5  depicts concrete mold  100  in a closed position. In the closed position, the side-panel members  116 A and  116 B are rotated toward the inner faces  114  and away from the outer faces  115  of the hold-down members  112 A and  112 B. This position of the side-panel members  116 A and  116 B relative to the hold-down members  112 A and  112 B forms a cavity into which concrete may be poured. In the closed position, the joints  128  between the side-panel members  116 A-C are sealed so that the mold  100  may contain the poured concrete without leaking. 
         [0037]    To ensure that the concrete mold  100  remains in a closed position during pouring and curing of concrete, the side-panel members  116 A and  116 B are locked relative to the hold-down members  112 A and  112 B with hold-down arrangements  150 . Each hold-down arrangement  150  may include a hold-down pin  134 , or a similar element, which locks the position of a side-panel  116 A or  116 B relative to the corresponding hold-down frame member  112 A or  112 B by simultaneously engaging the hold-down collar  122  and the hold-down post  123 . The hold-down pins  134  secure the hold-down collars  122  included on the hinge members  120  of the side-panel members  116 A-B to the corresponding hold-down posts  123  included on the hold-down members  112 A-B. One embodiment of this relationship is shown in  FIG. 8 . In the example shown, the hold-down pin  134  is integrated within the hold-down collar  122 , however the hold-down pin  134  may be in any other form which allows it to easily lock and unlock the side-panel members  116 A and  116 B relative to the hold-down members  112 A and  112 B by engaging and disengaging the hold-down collar  122  and the hold-down post  123 . For example, the hold-down pin  134  may be integrated within the hold-down post  123  or may be tethered to the hold-down member  112 A-B or otherwise connected to the mold  100 . 
         [0038]    While  FIGS. 4 and 5  show two hold-down arrangements  150  for each side-panel member  116 A-B and hold-down member  112 A-B, more or fewer hold-down arrangements  150  may be used. When the mold  100  is in the closed position, the hold-down arrangements  150  are inboard, closer to the cavity than the hinge members  120  which are outboard. 
         [0039]    Additionally, in alternative embodiments of the present disclosure, the side-panel members  116 A-B may be locked in position relative to the hold-down members  112 A-B by any other method which will prevent the side-panel members  116 A-B from rotating outwardly relative to the hold-down members  112 A-B. For example, latching the joints  128  of side-panel members  116 A-C together or applying diagonal cross-braces over the joints  128  between side-panel members  116 A-C may accomplish locking the side-panel members  116 A and  116 B in position relative to the hold-down members  112 A and  112 B to ensure that the side-panel members  116 A-B remain in the closed position against the lateral force applied by the poured concrete. 
         [0040]      FIG. 6  depicts poured concrete contained within the mold  100  in a closed position. The concrete poured within the cavity created by the side-panel members  116 A-C forms a concrete member  144 . The concrete member  144  may optionally encase reinforcements  146 , such as rebar. 
         [0041]    As depicted in  FIG. 7 , after the concrete member  144  within mold  100  has cured, the side-panel members  116 A and  116 B are unlocked from, and are rotated outwardly relative to, hold-down frame members  112 A and  112 B. This orients the mold  100  in the open position so that the concrete member  144  may be removed from the mold  100 . In the example of  FIG. 7 , side-panel member  116 A is rotated outwardly relative to hold-down member  112 A first, then side-panel member  116 B is rotated outwardly relative to hold-down member  112 B due to the shape of the chamfering at the joint  128  between the two side-panel members  116 A-B. 
         [0042]    The cured concrete member  144  may be pried from mold  100  while leaving side-panel members  116 A-C in their respective positions depicted in  FIG. 7 . The mold  100  allows the fixed side-panel  116 C to be used as a pivot to aid in prying concrete member  144  out of the mold  100 . In alternative embodiments, such as that of  FIG. 2  for example, each of side-panel members  116 A′,  116 B′,  116 C′ and  116 D′ may be hinged so that each may be unlocked and rotated outwardly relative to the hold-down members  112  to facilitate removing the member  144  from the mold  100 . The concrete member  144  may then be lifted vertically from the mold  100  or slidably removed from the mold  100 . In either embodiment, the side-panel members  116  may be returned to the closed position and locked to accept a new pour of concrete for forming a new concrete member  144 . 
         [0043]    In operation, the side-panel members  116 A-C are affixed to the hold-down frame of the mold  100 . When the hinged side-panel members  116 A-B are locked into a closed position relative to the hold-down members  112 A-C, the mold  100  is configured to contain poured concrete to form a concrete member  144 . After the concrete member  144  has cured within the mold  100 , the side-panel members  116 A-C can be unlocked relative to the hold-down members  112 A-C and moved into the open position. This allows the concrete member  144  to be removed quickly and easily from the mold  100  without the need to break-down the frame surrounding the concrete member  144 . After removing the concrete member  144 , the side-panel members  116 A-C may be returned to the closed position and re-locked relative to the hold-down members  112 A-C. The mold  100  may then be reused to cure another concrete member  144  without the need to rebuild the frame around the mold  100 . 
         [0044]    The foregoing detailed description of one or more embodiments of the concrete mold has been presented herein by way of example only and not limitation. It will be recognized that there are advantages to certain individual features and functions described herein that may be obtained without incorporating other features and functions described herein. Moreover, it will be recognized that various alternatives, modifications, variations, or improvements of the above-disclosed embodiments and other features and functions, or alternatives thereof, may be desirably combined into many other different embodiments, systems or applications. Presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the appended claims. Therefore, the spirit and scope of any appended claims should not be limited to the description of the embodiments contained herein.