EP2969438B1 - Procédé de fabrication d'un élément en nappe ayant une surface différente d'une surface plane - Google Patents

Procédé de fabrication d'un élément en nappe ayant une surface différente d'une surface plane Download PDF

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Publication number
EP2969438B1
EP2969438B1 EP14714571.8A EP14714571A EP2969438B1 EP 2969438 B1 EP2969438 B1 EP 2969438B1 EP 14714571 A EP14714571 A EP 14714571A EP 2969438 B1 EP2969438 B1 EP 2969438B1
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EP
European Patent Office
Prior art keywords
produced
mold
parts
mold parts
flat
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EP14714571.8A
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German (de)
English (en)
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EP2969438A1 (fr
EP2969438C0 (fr
Inventor
Thomas HENRIKSEN
Christian Raun Jepsen
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HENRIKSEN, THOMAS
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Individual
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Publication of EP2969438C0 publication Critical patent/EP2969438C0/fr
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/22Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/34Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/346Manufacture of moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/02Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
    • B28B7/025Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article the mould surface being made of or being supported by a plurality of small elements, e.g. to create double curvatures
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00Roofs; Roof construction with regard to insulation
    • E04B7/08Vaulted roofs
    • E04B7/10Shell structures, e.g. of hyperbolic-parabolic shape; Grid-like formations acting as shell structures; Folded structures
    • E04B7/102Shell structures

Definitions

  • the present invention relates to a method for producing a sheet-like element with a surface that deviates from a flat surface from hardening material, comprising the steps of the preamble of claim 1.
  • planar elements with a surface deviating from a flat surface are known from different materials and are used, for example, for cladding surfaces or facades of buildings in modern architecture.
  • planar elements made of glass the production of which deviates from a flat surface and, in particular, has a complicated curved shape is extremely complex and expensive
  • the use of such planar elements with different shapes deviating from a flat surface also made of hardenable materials such as plastics or concrete, in particular reinforced or fiber-reinforced concrete, is increasingly desired.
  • planar elements are extremely complex, with one possibility for the production of elements made of concrete, in particular reinforced or fiber-reinforced concrete, being, for example, spraying processes, with fiber reinforcements, for example textile fabrics being introduced into a corresponding form and then concrete with special physical properties in multi-stage spraying processes -chemical properties is applied.
  • spraying methods are extremely problematic, especially with regard to their control and implementation, and it is particularly difficult, taking into account the long production and, in particular, curing times, such planar elements with the desired and in particular the same properties, such as surface quality, color and the like to make large quantities available.
  • planar elements with a surface deviating from a flat surface arise, for example, from the fact that particularly for a connection or connection of adjacent planar elements in the edge or edge area, recessed or offset edge areas are often required, which compared to a Thickness of the sheet-like element to be produced have an additional extent or height.
  • production devices in particular casting devices, are known for the production of planar elements with elaborate or complex curved surfaces, wherein a casting mold with a surface that can be adjusted according to the shape of the element to be produced is provided, as is the case, for example, in WO 2012/065614 A1 or the DE 198 23 610 A1 is removable.
  • a casting mold with a surface that can be adjusted according to the shape of the element to be produced is provided, as is the case, for example, in WO 2012/065614 A1 or the DE 198 23 610 A1 is removable.
  • the use of such casting devices with an adjustable surface taking into account the extremely long curing times of up to 28 days, for example, is not economically viable.
  • the production of a large number of such planar elements, some of which may have different shapes, is not possible due to the lack of availability of a correspondingly large number of correspondingly complex casting devices.
  • a similar form for the production of components corresponding to the training mentioned above is, for example, from DD 137 423 A1 , which more specifically discloses the preamble of claim 1, has become known.
  • the present invention therefore aims to provide a method of the type mentioned above with which the above-mentioned problems of the prior art can be avoided or at least reduced and such flat elements with a surface made of hardening material that deviates from a flat surface in possibly large numbers and with possibly differing shapes with a reduced expenditure of time, a constant quality and in particular with reduced costs can be made available in an economically sensible manner.
  • the molded parts are arranged at a distance from one another or a cavity or depression is provided in at least one of the surfaces of the molded parts.
  • the hardening material can then be easily and reliably introduced into the cavity delimited by the mold parts, with any necessary or desired reinforcements of such a hardening material also being easily and reliably introduced into the cavity between the mold parts.
  • the mold parts By providing the mold parts, they can also remain connected to one another for long periods of time that may be required for curing of the planar element to be produced, after which the mold parts can be opened and the cured planar element can be removed.
  • spacers be used to form the distance between the molded parts in accordance with the external dimensions of the planar element to be produced. According to the thickness of the element to be produced, such spacers can easily be arranged between the molded parts to be connected to one another and at the same time define the external dimensions of the planar element to be produced. Since the planar elements to be produced should have a shape deviating from a flat surface or a surface lying in a plane, elastic spacers are preferably provided or used according to the invention, which can be easily and reliably connected between the can arrange connecting moldings.
  • planar elements can be provided which, for example, can be designed in accordance with architectural requirements with edge or edge regions having a greater height or thickness for a proper and aesthetically pleasing connection to adjacent planar elements.
  • the planar element to be produced is formed by a curved surface, it being proposed according to a further preferred embodiment in this context that the curved surface be a single-curved or double-curved surface or Surface is formed with free shaping.
  • the method according to the invention can thus be used to provide planar elements made of hardening material with a complicated and complex shape which, if at all realizable, could only be produced with other production methods with extremely increased expenditure of time and money.
  • the molded parts can be easily and reliably provided with the desired curved surfaces corresponding to the shape of the sheet-like element to be produced, whereby if desired the surfaces of the sheet-like element to be produced do not necessarily have to be identical on both sides, so that additional, for example structural features, for example for Achieving corresponding mechanical strengths can be taken into account.
  • the hardening material is selected from plastics, in particular polyester and epoxy, glass, plaster, concrete, in particular reinforced or fiber-reinforced concrete, or the like of the technology in the production of such planar elements made of concrete, in particular fiber-reinforced concrete, so that the advantages of the method according to the invention in connection with the use of fiber-reinforced concrete are immediately apparent.
  • the hardening material is introduced between the two mold parts under vacuum.
  • the molded parts are positioned relative to one another using at least one marking.
  • the molded parts are opened non-destructively and reused after removal of the element to be produced. Such a reusability allows additional cost advantages to be achieved in connection with the costs for the production of the molded parts.
  • a molded part for use in a method according to the invention of the type mentioned above is essentially characterized in that the molded part is formed with a cavity or a recess corresponding in particular to the thickness of the element to be produced, and that the molded part is formed with a recess corresponding to a recessed or stepped edge or edge region on the side of the element to be produced facing away from the outer surface.
  • Such moldable or castable or foam-like materials are available in different material compositions and can therefore be selected and used to produce the molded parts, for example in adaptation to a desired shape and in particular to the materials to be used for the sheet-like material to be produced.
  • the molded part is provided with a cavity or a depression, in particular accordingly the thickness of the element to be produced.
  • the molded part is designed with a depression corresponding to a recessed or offset edge or edge area of the element to be produced.
  • the molded part is designed with at least one marking for positioning.
  • a further preferred embodiment provides that the marking is formed by a through hole outside the surface of the element to be produced.
  • a plurality of markings, in particular holes be provided along the circumference of the surface of the element to be produced.
  • a method for producing a molded part according to the invention of the type mentioned above is essentially characterized in that, for the formation of undercut or offset edge or edge regions on the side of the planar element to be produced and facing away from the outer surface, /or a cavity or depression on the molded part inserts are placed on the adjustable surface of the mold.
  • inserts are arranged on the adjustable surface of the casting mold to form undercut or offset edge or edge regions of the planar element to be produced and/or a cavity or a depression on the molded part.
  • At least one marking is provided for mutual positioning of the molded parts.
  • the marking is formed by a through hole outside the surface of the element to be produced.
  • the hardening material is selected from plastics, in particular polyester and epoxy, reinforced or fibre-reinforced, in particular glass-fibre reinforced plastics, glass, plaster, concrete, in particular reinforced or fibre-reinforced concrete or the like.
  • FIG. 1 are schematic individual process steps for the production of a molded part for use in a subsequent process for the production of a planar element with a surface deviating from a flat surface made of hardening material, as is the case in particular in 3 is shown in more detail.
  • Fig. 1a shows schematically a portion of a casting mold, as shown in detail in Figures 4a and 4b is shown in more detail, the casting mold 1 having a surface 2 which can be adjusted in accordance with the surface of the planar or plate-like or shell-like or planar element to be produced.
  • the surface 2 of the casting mold 1 and thus of the planar element to be produced subsequently as is shown in 3 , in particular 3g is shown, has a shape deviating from a flat surface in the form of a complex curvature.
  • the curved surface can be formed by a single-curved or double-curved surface or free-form surface.
  • corresponding boundary walls 3 are arranged to limit the external dimensions of the molded part to be produced, with rod-like elements 4 also being indicated, which, as will become apparent below, are markings in shape of holes or openings in the molded part to be produced.
  • the boundary walls 3 and the rod-like elements 4 are removed after a moldable or castable or foam-like material has been introduced to form a first molded part 5 .
  • a foam-like material in particular, has very short curing times, for example, so that with such a casting mold or casting device 1, which has a surface 2 that can be adjusted according to the shape of the planar element to be produced, a large number of mold parts can be used quickly and inexpensively to shape a product to be produced sheet-like element of complementary shape can be produced.
  • Fig. 1d is indicated schematically how the molded part 5 produced is removed from the casting mold and its adjustable surface 2 according to the arrow 6 .
  • the molded part 5 is thus formed with a surface 7 that is likewise curved in a complex manner corresponding to the surface 2 .
  • the markings 8 formed by holes or openings can also be seen.
  • FIG 2 shows the production of a second molded part for the subsequent production or formation of a planar element with a surface that deviates from a flat surface, with the in Figures 2a to 2d
  • the process steps shown are essentially identical to those in Figures 1a to 1d illustrated process steps are.
  • Figure 2a is a mold denoted by 11 again with an adjustable surface 12 corresponding to the shape of the sheet-like to be produced Elements provided, in addition to the embodiment according to Fig. 1a in the representation according to Figure 2a a frame-shaped insert 13 is placed on the surface 12.
  • the frame-shaped insert 13 can be made of a suitably elastic material, for example, in order to, as is shown in Figure 2a is indicated to follow the complex curvature of the surface 12 as well.
  • FIG 2b is shown how boundary walls 14 and rod-like positioning elements 15 are arranged on the surface 12 for the production of the second molded part, whereupon in the in Figure 2c In the method step shown, these elements 14 and 15 are removed again, so that a second molded part 16 was produced by a previous introduction and curing of a material that is moldable or castable or foam-like in turn.
  • This second molded part 16 is in Fig. 2d again shown in the position removed from the mold 11 and the surface 12 according to the arrow 17, again markings 18 formed by holes being indicated.
  • This second molded part 16 is in Figure 2e shown in a plan view, from which it can be seen that in addition to a correspondingly complex curved surface 19 and the marking holes 18, which are provided outside of the sheet-like element to be subsequently produced, a depression 20 is formed in the surface 19, which is subsequently formed during the production of the sheet-like element will form remote or receding edge or edge areas with a correspondingly increased thickness.
  • a particularly elastic Spacer 21 is arranged, the height of which is greater than the depth of the depression 20, so that the spacer 21 protrudes over the surface 19 of the molded part 16, as is shown in 3c is shown and for example in the detailed representations of Figures 4e and 4f will become more apparent.
  • the molding 16 which is provided with the spacer 21 in the recess 20, which according to the method of 1 manufactured molding 5 approximated, as indicated by the double arrow 22 and in Figure 3e is shown in greater detail.
  • positioning rods 23 are arranged in the marks formed by holes 8 and 18 respectively.
  • a planar element with a surface that deviates from a flat surface can be produced from hardening material.
  • This planar element is shown schematically in 3g and designated 24 with the undercut edge portions produced by the depression 20 being indicated at 25 and the curved surface being generally indicated at 26.
  • Figures 4a and 4b 31 denotes a casting device, which has an adjustable surface 32, with adjusting elements, which are formed, for example, by telescopic elements, being denoted by 33. It is immediately apparent that with a corresponding adjustment of the adjustment elements 33 essentially any desired shape of the surface 32, which of a flexible element, for example a flexible mat, can be achieved, so that instead of the surface 32 shown as a flat surface for the sake of simplicity, the Fig. 1a and 2a illustrated complex surfaces 2 and 12 can be achieved.
  • a frame-shaped insert 36 is provided or arranged on the surface 32, which during the production of the molded part will produce a depression defining the formation of recessed or offset edge or edge regions of the planar element to be produced.
  • Figure 4b is a procedural step similar to the procedural step Figure 2c shown, where after the introduction of a castable or moldable or foam-like material, boundary walls (not shown in detail) and rod-like centering elements 34 are removed, so that the outer contours of a molded part 35 produced become visible.
  • This molded part 35 has marking or positioning elements 37 formed by holes corresponding to the rod-like centering elements.
  • Figure 4d is in a to Figure 4c Similar representation schematically shows a second molded part 39, which is formed by the in Figures 4a and 4b is generated schematically indicated manufacturing steps, wherein marking elements 40 are provided.
  • this molded part 39 has no depressions or cavities.
  • FIG Figure 4e strip-shaped spacers 41 are arranged in the molded part 35 in its depression 38 .
  • Figure 4 shows the mold parts 35 and 39 in assembled condition, as shown Fig. 3f is equivalent to. From this representation it can be seen that the molded parts 35 and 37 are positioned relative to one another by rod-like centering elements 42 which are arranged in the markings 37 and 40 of the molded parts 35 and 39 formed by passage openings or holes. Out of Fig. 4f It can also be seen that the facing surfaces of the mold parts 35 and 39, which define the outer surfaces of the sheet-like element to be produced, are arranged at a distance from one another, the thickness of the sheet-like element to be produced being defined by the protruding height of the strip-shaped spacers 41 .
  • the planar element to be produced is formed by introducing the hardening material into the cavity between the mold parts 35 and 39, with corresponding introduction or feed openings not being shown in detail.
  • the mold parts 35 and 39 are separated from one another, in particular after the rod-shaped centering elements 42 have been removed, so that the planar element produced can subsequently be removed. Since a non-destructive separation of the mold parts 35 and 39 with subsequent removal of the planar element to be produced is possible, these mold parts can in turn be used to produce a further planar element.
  • FIG 5a a perspective view of a planar element 43 produced by the mold parts 35 or 39 can be seen. It is immediately apparent that in the formation of curved or complex outer surfaces, as in the Figures 1 to 3 is indicated schematically, instead of in figure 5 shown and with the molded parts according to 4 produced sheet-like planar element such a Element would have a corresponding curvature or complex shape, as is shown schematically in 3g shown and designated 24.
  • the produced planar element 43 has a circumferential recessed or offset edge or edge region 44, which is often desired or required in particular for an assembly with adjacent or adjoining planar elements.
  • FIG. 4f Similar representation shown a modified embodiment of molded parts 45 and 46 in the assembled state. From this representation it can be seen that the molded part 45 is not only similar to that in Figure 4c embodiment shown has a recess 47 to form a circumferential stepped edge or edge region, but that the partial region 48 of the molded part 45 lying between the circumferential edge regions 47 is recessed or stepped in relation to the outer surface 49 to determine the thickness of the planar element to be produced is and defines such a cavity, which when assembled with the further molded part 46, as in 6 is shown, directly defines the thickness of the planar element to be produced.
  • a distance between the mold parts 45 and 46 is not required.
  • the recess 48 defines a cavity to the boundary surface 50 of the further molded part 46, so that when the cavity between the surfaces of the molded parts 45 and 46 is filled, a flat element can be provided with a shape as shown in figure 5 is shown in detail.
  • planar elements 24 can be produced with essentially any desired curvature or general surface by providing molded parts with a corresponding shape.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Claims (13)

  1. Procédé de fabrication d'une première pièce moulée (5, 35), d'une seconde pièce moulée (16, 39) et d'un élément en nappe (24, 43) ayant une surface en matériau durcissant différente d'une surface plane, comprenant les étapes suivantes :
    - fabrication d'une première pièce moulée (5, 35) dans un moule de coulée (1) à surface réglable (2), lequel présente une première surface de moule (7) qui a une forme correspondant à une surface de l'élément à fabriquer (24, 43) ,
    - fabrication d'une seconde pièce moulée (16, 39) dans un moule de coulée (11) à surface réglable (12), lequel présente une seconde surface de moule (19) qui a une forme correspondant à une autre surface de l'élément à fabriquer (24, 43),
    - assemblage des première et seconde parties de moule (5, 16, 35, 39), moyennant quoi un espace et/ou une cavité ou un creux est délimité par la première pièce moulée (5, 35) et la seconde pièce moulée (16, 39) entre au moins l'une des surfaces des pièces moulées (5, 16, 35, 39) correspondant à l'élément (24, 43) à fabriquer,
    - introduction du matériau durcissant dans la cavité délimitée par les pièces moulées (5, 16, 35, 39),
    - durcissement du matériau durcissant dans les pièces moulées assemblées ensemble (5, 16, 35, 39), et
    - ouverture des pièces moulées (5, 16, 35, 39) et retrait de l'élément en nappe durci (24, 43),
    caractérisé en ce
    qu'une cavité dans la surface du moule (7, 19) est formée pendant la fabrication d'au moins l'une des première et seconde pièces moulées (5, 16, 35, 39) par des inserts (13, 36) sur la surface réglable du moule de coulée (1, 11) .
  2. Procédé selon la revendication 1, caractérisé en ce que des entretoises (21, 41) correspondant aux dimensions extérieures de l'élément en nappe (24, 43) à fabriquer sont utilisées pour former la distance entre les pièces moulées (5, 16, 35, 39).
  3. Procédé selon la revendication 1 ou 2, caractérisé en ce qu'une surface de l'élément en nappe (24, 43) à fabriquer est au moins partiellement conçue avec une zone de bord ou d'arête en retrait ou décalé (25, 44).
  4. Procédé selon la revendication 1, 2 ou 3, caractérisé en ce qu'au moins une surface de l'élément en nappe (24, 43) à fabriquer est formée par une surface courbe (26, 50).
  5. Procédé selon la revendication 1, 2, 3 ou 4, caractérisé en ce que les entretoises (21, 41) sont conçues de manière élastique.
  6. Procédé selon la revendication 4, caractérisé en ce que la surface courbe (26, 50) est formée par une surface à simple courbe ou à double courbe ou par une surface de forme libre.
  7. Procédé selon l'une des revendications 1 à 6, caractérisé en ce que le matériau durcissant est choisi parmi les matières plastiques, en particulier le polyester et l'époxy, le verre, le plâtre, le béton, en particulier le béton armé ou renforcé par des fibres, ou analogues.
  8. Procédé selon l'une des revendications 1 à 7, caractérisé en ce que la matière durcissante est introduite sous vide entre les deux pièces moulées (5, 16, 35, 39).
  9. Procédé selon l'une des revendications 1 à 8, caractérisé en ce que les pièces moulées (5, 16, 35, 39) sont positionnées les unes par rapport aux autres à l'aide d'au moins un marquage (8, 18, 37, 40).
  10. Procédé selon l'une des revendications 1 à 9, caractérisé en ce que les pièces moulées (5, 16, 35, 39) sont ouvertes de manière non destructive et sont réutilisées après le retrait de l'élément (24, 43) à fabriquer.
  11. Procédé selon l'une des revendications 1 à 10, caractérisé en ce que, pour former des zones de bord ou d'arête (25) en retrait ou décalées de l'élément (24) en nappe à fabriquer, des inserts (13) sont disposés sur la pièce moulée (5, 16) sur la surface réglable du moule de coulée (1), dans lequel la pièce moulée (5, 16) est fabriquée dans un matériau pouvant être moulé ou coulé ou de type mousse ou en matière plastique.
  12. Procédé selon la revendication 9, caractérisé en ce que le marquage (8, 18, 37, 40) est formé par un trou traversant à l'extérieur de la surface (26, 50) de l'élément (24, 43) à fabriquer.
  13. Procédé selon l'une des revendications 9 ou 12, caractérisé en ce que plusieurs marquages (8, 18, 37, 40), en particulier des trous, sont formés le long de la circonférence de la surface (26, 50) de l'élément (24, 43) à fabriquer.
EP14714571.8A 2013-03-13 2014-03-11 Procédé de fabrication d'un élément en nappe ayant une surface différente d'une surface plane Active EP2969438B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ATA194/2013A AT514035B1 (de) 2013-03-13 2013-03-13 Verfahren zur Herstellung eines flächenartigen Elements mit von einer ebenen Oberfläche abweichender Oberfläche, Formteil zur Herstellung sowie flächenartiges Element
PCT/AT2014/000046 WO2014138759A1 (fr) 2013-03-13 2014-03-11 Procédé de fabrication d'un élément en nappe ayant une surface différente d'une surface plane, partie de moule servant à fabriquer un tel élément en nappe, et élément en nappe

Publications (3)

Publication Number Publication Date
EP2969438A1 EP2969438A1 (fr) 2016-01-20
EP2969438B1 true EP2969438B1 (fr) 2023-06-07
EP2969438C0 EP2969438C0 (fr) 2023-06-07

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AT (1) AT514035B1 (fr)
WO (1) WO2014138759A1 (fr)

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US10987832B2 (en) 2016-03-08 2021-04-27 Adapa Aps Method and an apparatus for making a three-dimensional object and a membrane therefore

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DD137423A1 (de) * 1978-06-23 1979-09-05 Ursula Eisel Form
JPH0716820A (ja) * 1993-06-30 1995-01-20 Planning Tenshiyon:Kk 造形物形成用の型材及びそれを用いた造形物の形成方法並びにそれにより得られた造形物
NL2004864C2 (en) * 2010-06-09 2011-12-13 Infra & B V Moulds and methods for forming prefab concrete floor elements and prefab elements.
AT510664B1 (de) * 2010-10-20 2012-09-15 Technologiezentrum Ski Und Alpinsport Gmbh Bauwerk mit mindestens einem gekrümmten konstruktionselement aus beton sowie ein verfahren zur erstellung eines derartigen bauwerks

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WO2014138759A1 (fr) 2014-09-18
EP2969438A1 (fr) 2016-01-20
AT514035A1 (de) 2014-09-15
EP2969438C0 (fr) 2023-06-07
AT514035B1 (de) 2016-03-15

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