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.

What is claimed is: 
     
         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.