Method and apparatus for casting structures

Abstract

An interior mold form is disclosed, which creates arch-shaped hollows inside a cast material. The form may be used to cast the material into structures as strong as solid structures, but having less weight. More efficient use of material saves on material costs. The mold form creates arch-like hollows in two perpendicular directions within the material, to provide strength against stresses in multiple directions. A process of casting, using the mold is described. An exemplary mold formed of polystyrene is applied to concrete casting. Structures, including those cast of concrete, using the mold and process are also disclosed.

1 . An interior mold form for casting a structure, comprising: 
 a sheet of material, having a first side having a surface and a second side having a surface, comprising:    a first plurality of parallel, ridges, disposed on the first side of the sheet, the ridges being parallel to the first side surface    
   
   
       2 . The interior mold form of  claim 1 , further comprising: 
 a second plurality of parallel ridges, disposed on the second side of the sheet, the ridges being parallel to the second side surface.    
   
   
       3 . The interior mold form of  claim 2 , wherein the first plurality of ridges and the second plurality of ridges are non-parallel.  
   
   
       4 . The interior mold form of  claim 3 , wherein the first plurality of ridges and the second plurality of ridges are substantially perpendicular.  
   
   
       5 . The interior mold form of  claim 1 , wherein the ridges of the first plurality of ridges are roughly semi-cylindrical in shape.  
   
   
       6 . The interior mold form of  claim 5 , further comprising a second plurality of ridges, roughly semi-cylindrical in shape.  
   
   
       7 . The interior mold form of  claim 6 , further comprising: 
 a first plurality of troughs, disposed between each ridge of the plurality of ridges; and    a second plurality of troughs, disposed between each ridge of the second plurality of ridges.    
   
   
       8 . The interior mold form of  claim 7 , wherein the first plurality of ridges and second plurality of ridges are non-parallel.  
   
   
       9 . The interior mold form of  claim 8 , wherein the first plurality of ridges and second plurality of ridges are substantially perpendicular.  
   
   
       10 . The interior mold form of  claim 9 , wherein the first plurality of troughs and the second plurality of troughs intersect, the intersections of the troughs forming apertures through the sheet of material.  
   
   
       11 . The interior mold form of  claim 10 , formed of polystyrene or fiberglass.  
   
   
       12 . The interior mold form of  claim 10 , formed of 2-lb polystyrene.  
   
   
       13 . The interior mold form of  claim 6 , wherein the first and second plurality of ridges comprise semi-cylindrical segments and roughly flat bases.  
   
   
       14 . An interior mold form, comprising a plurality of arched bumps.  
   
   
       15 . The interior mold form of  claim 14 , wherein the bumps are arrayed on a planar support.  
   
   
       16 . A mold, comprising: 
 one or more exterior retaining-sides;    an interior mold form; and    means of securing the interior mold form within the mold.    
   
   
       17 . The mold of  claim 16 , wherein the interior mold form comprises: 
 a sheet of material, having a first side having a surface and a second side having a surface, comprising: 
 a first plurality of parallel, ridges, disposed on the first side of the sheet, the ridges being parallel to the first side surface  
 a second plurality of parallel ridges, disposed on the second side of the sheet, the ridges being parallel to the second side surface.  
   
   
   
       18 . The mold of  claim 17 , wherein the interior mold form further comprises: 
 a first plurality of troughs, disposed between each ridge of the plurality of ridges; and    a second plurality of troughs, disposed between each ridge of the second plurality of ridges    
   
   
       19 . An interior molding form, made by a process comprising: 
 a. Providing a sheet of material having a first side and a second side;    b. Machining a first plurality of parallel ridges into the first side of the sheet.    
   
   
       20 . The interior molding form of  claim 19 , wherein the first plurality of parallel ridges are separated by troughs.  
   
   
       21 . The interior molding form of  claim 20 , wherein the process further comprises: 
 c. Machining a second plurality of parallel ridges separated by troughs on the second side of the sheet.    
   
   
       22 . The interior molding form of  claim 21 , wherein the first and second plurality of ridges are roughly perpendicular.  
   
   
       23 . The interior molding form of  claim 22 , wherein the sheet of material is 2-lb polystyrene.  
   
   
       24 . The interior molding form of  claim 23 , further comprising positioning rods.  
   
   
       25 . An interior mold form for casting a material, comprising: 
 means for displacing the material to be cast, from within the material, for forming a regular interior structure.    
   
   
       26 . The interior mold form of  claim 25 , further comprising: 
 means for securing the interior mold form within an external mold.    
   
   
       27 . A method for casting, comprising: 
 a. Providing a material to be cast    b. Providing an interior mold form, capable of displacing the material to be cast;    c. Providing exterior mold sides;    d. Forming a mold, comprising the interior mold form, retained inside the exterior mold sides;    e. Substantially filling the mold with the material to be cast; and    f. Hardening the material.    
   
   
       28 . The method of  claim 27 , wherein the interior mold form is polystyrene.  
   
   
       29 . The method of  claim 28 , wherein the material to be cast is concrete.  
   
   
       30 . The method of  claim 29 , further comprising: 
 g. Positioning reinforcing bars within the mold.    
   
   
       31 . The method of  claim 30 , further comprising: 
 h. Securing the interior form against the reinforcing bars with plastic rods.    
   
   
       32 . A method for casting a material with internal structure, comprising: 
 a. Providing a volume in which a material to be cast may be retained;    b. Providing one or more material displacing forms within the volume;    c. Substantially filling the volume with the material to be cast; and    d. Hardening the material.    
   
   
       33 . The method of  claim 32 , wherein the one or more material displacing forms comprise ridges.  
   
   
       34 . The method of  claim 33 , wherein the one or more material displacing forms comprise polystyrene  
   
   
       35 . A cast structure, formed by the process of: 
 a. Providing an interior mold form;    b. Providing an exterior mold side;    c. Forming a mold, comprising the interior mold form, retained inside the exterior mold side;    d. Substantially filling the mold with a material to be cast; and    e. Hardening the material.    
   
   
       36 . The cast structure of  claim 35 , wherein the interior mold form, comprises: 
 a sheet of material, having a first side surface and a second side surface, comprising: 
 a first plurality of parallel, roughly semi-cylindrical ridges, disposed on the first side of the sheet, having axis parallel to the first side surface; and,  
 a second plurality of parallel, roughly semi-cylindrical ridges, disposed on the second side of the sheet, having axis parallel to the second side surface, and perpendicular to the axis of the first plurality of ridges;  
 a first plurality of troughs, disposed between each ridge of the plurality of ridges; and  
   a second plurality of troughs, disposed between each ridge of the second plurality of ridges.    
   
   
       37 . The cast structure of  claim 36 , wherein the interior mold form, is formed from one of polystyrene, fiberglass, plastic, or ceramic.  
   
   
       38 . The cast structure of  claim 37 , wherein the material to be cast is concrete.  
   
   
       39 . The cast structure of  claim 38 , wherein the process further comprises: 
 f. Providing reinforcing bars within the troughs of the interior mold form.    
   
   
       40 . The cast structure of  claim 39 , wherein the process further comprises: 
 g. Positioning the interior mold relative to the reinforcing bars to allow the flow of material around the mold and reinforcing bars.    
   
   
       41 . A method for casting a horizontally aligned structure, comprising: 
 a. preparing a flat area of ground for concrete application;    b. pouring a first layer of concrete;    c. positioning a mold form over the thin layer of concrete; and    d. pouring a second layer of concrete over the mold form.