HK1138048A - Architectural membrane structures and methods for producing them - Google Patents

Description

Architectural membrane structure and method for producing same

RELATED APPLICATIONS

Priority of the present application claims U.S. provisional application No.60/896,664 filed on 23/3/2007, U.S. provisional application No.60/896,904 filed on 24/3/2007, and U.S. provisional application No.60/908,057 filed on 26/3/2007. The teachings of these applications are incorporated herein by reference in their entirety.

Background

Building membranes, also known as tension or tensioned structures, are increasingly being used for the construction of airports, storage facilities, arenas, activity centers, sports or meeting grounds, domes, museums, houses and the like. Architectural membranes provide great design flexibility in roofing, skylights, overhung, and other containment (envelope) structures. They can be conventionally made in various shapes. Pre-assembled modules may also be utilized.

Examples of existing designs that have been introduced into architectural membranes include the Talismancenter in Carrageenan, Canada, Millennium Dome, Denver International airport, air-supported roofs such as those used in Indianapolis RCDome, and many others.

Known technical, code, and industry standards, such as those set forth by the American Society for Testing and Materials (ASTM), may be used to characterize lighting, energy, durability, or acoustic properties, and fire resistance of architectural membranes. For example, light transmittance and spectral reflectance can be determined using ASTM E424; acoustic properties can be determined using astm e-90; and fire performance can be determined using ASTM E-108 or ASTM E-84.

Existing architectural membranes include the known name supplied by Saint-Gobain CorporationThose of (a). In general,the building film being textile-basedCoated glass fiber fabric. In the actual installation of the device, the device is,construction membranes are often used with one or more additional liners designed to minimize acoustic interference, for example. For example, in Birdair's Technical Specification available from www.birdair.com&Description in textile CharacteristicsDescribe several typesThe features of the architectural membrane, the teachings of which are incorporated herein by reference in their entirety.

Generally, architectural membrane based envelopes are lighter than permanent structures, can be more easily installed and removed, and tend to withstand destructive forces such as earthquakes.

The design of architectural membranes typically takes into account some of the same criteria as are considered when designing conventional buildings, such as base load, wind pressure, and other criteria. Such standards are defined by local building codes or template codes that have jurisdiction. In addition, the design method may also include principles related to tensile geometry, shape generation, biaxial performance, stress and structural analysis of the film, and the like.

With the increasing demand for energy conservation and "green" building materials and practices, there remains a need for lightweight building films that maintain flexibility in the design and applications in which they are typically used and still provide improved light transmission and good thermal insulation. There is also a need for systems with improved acoustic properties and high reflectivity, e.g. UV reflectivity properties.

Disclosure of Invention

The present invention relates generally to structures that may be used in architectural and/or structural fabric applications. Many preferred aspects of the present invention relate to architectural membrane structures comprising materials having insulating or light transmissive properties, and preferably both insulating and light transmissive properties.

Materials that may be incorporated into the architectural membrane structures of the present invention include aerogels and other materials, for example, porous, such as microporous or nanoporous (nanopous) materials. In a particular example, the material is granular. In other examples, the material is a monolithic (monolith) or composite material. In still other examples, the material has a thermal conductivity (k value) that remains substantially unchanged and preferably decreases with load and/or compression. In a further example, the structure comprises a load-bearing insulator.

In a specific implementation of the invention, the architectural membrane structure is a multi-layer structure. For example, the structure includes: a first layer, a second layer, and a material such as monolithic aerogel or particulate aerogel, or aerogel composite, between the first layer and the second layer. Arrangements may also be employed in which the aerogel or another suitable material is adhered or otherwise secured to a single layer.

Aspects of the invention also relate to architectural membrane structures having a thermal conductivity or k-value that remains substantially unchanged or decreases with load and/or compression.

In many implementations, the architectural membrane of the present invention has one or more of the following properties: greater than 0.25%, preferably greater than 0.5%, and up to 0.80% and higher; a reflectance of at least 60%, preferably at least 70%, more preferably 80% and higher; a solar heat gain coefficient of at least 0.05; an R value of 3 to 38; and/or other properties as described further below.

Embodiments of the present invention also relate to methods of manufacturing architectural membrane structures. In one example, the method includes securing an aerogel material between a first layer and a second layer.

Embodiments of the present invention may be used in buildings or structural enclosures such as roofs, ceilings, walls, overhangs, air-supported structures such as air cushions or air pillows, and other building elements, where the structures disclosed herein may replace existing building membranes made from flexible, coated or laminated structural fabrics or membranes and may meet imposed load requirements and transfer the load to a support element.

Like conventional architectural membranes, the structures of the present invention are lightweight, have tensile properties suitable for use in textile structure technology and can support significant amounts of snow. Which can be designed for various shapes and applications and can have good durability and fire resistance. In many cases, the structure is translucent, thereby reducing or minimizing the need for room lighting. Which preferably has good insulating properties and may help reduce heating and/or cooling requirements and costs. In some embodiments, the present invention makes it possible to utilize a lighter, more translucent textile element than existing insulation systems to achieve the same overall strength and at a lower cost.

For example, the sandwich-type composites disclosed herein may be employed more thanExisting systems of membranes are thin. The three layer arrangement used in some aspects of the present invention may also be simpler and easier to manufacture than some of the existing membrane systems that include four or more layers. In many cases, when the base film or layer of the sandwich-type composite material of the present invention is installed and tensioned, it is used as a structure and thus can function as a barrier to the enclosed space, so that installation and finishing (finish) can be safely performed at an early stage during the construction process.

Drawings

In the drawings, like reference characters designate like parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the drawings:

FIG. 1 is a cross-sectional view of a building or structural composite of the present invention showing an outer layer and an insert or inner layer.

Fig. 2 is a cross-sectional view of a device including a fastening system for securing the building or structural composite of the present invention.

Figure 3 is a cross-sectional view of another device including another fastening system for securing the building or structural composite of the present invention.

Fig. 4A is a cross-sectional side view of a building including a roof that may employ the composite material of the present invention.

Fig. 4B is a top view of the building shown in fig. 4A.

Detailed Description

The above and other features of the invention, including various details of construction and combination of parts, and other advantages thereof, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It should be understood that the particular methods and apparatus embodying the invention are shown by way of illustration and not as limitations of the invention. The principles and features of this invention may be employed in many different embodiments without departing from the scope of the invention.

The present invention relates generally to architectural and/or structural elements, and more particularly to "fabric structures," which are also referred to herein as "architectural membrane structures," "architectural structures," or simply "structures" or "composites," the last two terms being used interchangeably. In many embodiments, the present invention relates to building structures that are flexible and multi-layered (i.e., have two or more layers).

In some aspects, the structure is a tensile or tensile structure that is typically loaded only with tensile stress and no compression or bending. In particular examples, the structures disclosed herein meet the proposed industry standard of loading only tensile or shear forces in the plane of the film.

In other aspects, the structures may be used as a replacement for existing building membranes employed in structural fabric applications such as tensile membranes, air-supported building membranes, air cushions or pillows, pleated membranes, tensioned monolithic support membranes, truss and dome supported flexible cladding, building facades, roofs, building envelopes, and the like. Existing architectural fabrics can be classified as either permanent structures or movable structures, and the composite materials disclosed herein can be used in combination with or as a replacement for both structures.

In a specific implementation of the invention, a composite or structure includes a first layer, a second layer (these layers are also referred to herein as "outer layers"), and an inner layer (also referred to herein as an "insert layer" or "insert") between the first and second layers. For example, a three layer structure 10 including outer layers 12 and 14 and an insert 16 sandwiched therebetween is shown in FIG. 1. With respect to the actual enclosure installation, the outer layers may refer to the bottom layer and the top layer, wherein the top layer faces outwardly from the interior of the building structure. One or both of the outer layers may be provided with one or more liners or coatings. One or both layers may be tensioned during installation.

Additional layers and/or inserts may be employed. For example, a first insert may be stacked on a first layer and covered with a second layer that in turn supports a second insert covered with an additional layer having an optional insert and further layers disposed thereon.

In some aspects of the invention, one or more inner layers (not shown in fig. 1) may be present, for example, disposed in the insert. In other aspects, at least one additional outer layer (also not shown in fig. 1) is disposed above or below the top layer or bottom layer, respectively.

These layers may be used to improve properties desired in the overall structure, such as increasing overall strength, increasing abrasion resistance, providing desirable acoustic, solar, and/or optical properties. The inner layer and/or additional outer layers may extend across the entire surface of the structure or may be disposed in specific areas.

The outer layers may be the same or different. Existing fabrics or architectural membranes, or layers thereof, may be used. One of the outer layers may be, or both of the outer layers may be, a reinforcing fabric membrane. A non-structural outer layer may also be used. One of the outer layers or both of the outer layers may include a liner or may be a composite material itself. The membranes used in the air-supported structures may also serve as one or both of the outer layers.

The outer layers are sized and shaped to meet construction and design specifications and may have the same or different thicknesses. The layer thickness can be, for example, at least about 0.10 millimeters (mm) and up to about 60 mm. Typically, the layer has a thickness of about 22mm to about 40 mm.

In one example, one of the outer layers comprises a textile material or both of the outer layers comprise a textile material. In another example, one of the outer layers is nonwoven or both of the outer layers are nonwoven.

In a preferred aspect of the invention, at least one of the outer layers is translucent, and preferably both of the outer layers are translucent. Outer layers having structural resistance, fire resistance, UV resistance, mold resistance, water resistance and/or weather resistance are preferred.

Materials that may be used to make one or both of the outer layers include, but are not limited to, fiberglass, mesh materials such as metal mesh, fiber batting (fiber batting), aramid, olefin, nylon, acrylic, polyester, natural fibers such as cotton, halogenated polymers such as Polytetrafluoroethylene (PTFE) (which may be, for example, available under the trade name teflon @)Obtained), and the like, as well as combinations of materials. It is also possible to use flakes (foil), such as those made of ethylene-tetrafluoroethylene (ETFE), which may be for example of the brand nameFrom Dupont.

Whether woven or non-woven, the first and/or second layer may be coated with PTFE, vinyl such as polyvinyl chloride (PVC), silicone, polyurethane, acrylic, titanium dioxide (TiO)₂) Other materials, or combinations thereof. What is needed isThe coating may be applied by painting, dipping, spraying, vapor deposition techniques, lamination, or other methods known in the art.

In one embodiment, at least one of the outer layers is made from Saint-Gobain corporationThe film material is made, and preferably both of the outer layers are made from Saint-Gobain CorporationA membrane material. Other commercially available PTFE coated fiberglass membranes that can be used include those of Taconic International ltdFilm, Verseidegseeee US IncOr Chukoh chemical industries LTD. Also suitable are expanded woven ptfe (eptfe) membranes, such as w.l. gores asoc.incThose of (a).

Commercially available silicone-coated fiberglass films that can be utilized include FabrimaxOf InterglasAnd Ferrari textures300. Silicone coated polyester films developed by PD InterglasThose. The solution dyed polyester film is commercially available as Weatherman from Safety Components Fabric Technologies IncOr Fireset from Glen Raven custom fabrics l.l.c

Olefin-based films include those known under the name Nova-From Inter Wrap under the nameAnd the name from Synthesis FabricsThose of (a). Examples of olefin open weave lock-knit meshes (olefin open weave lock-knitmes) include those of Solarfab incAnd of Gale PacificTextile polyvinylidene fluoride (PVDF) is available from Duckers&Friends under the trade markCommercially available.

Commercially available acrylic resin coated polyesters that can be used to form the first and/or second layers include Main from John BoyleGranitOf even Specialty FabricsAnd Marchem coated Fabrics Inc

Photovoltaic films such as PowerFilm incAnd Power of Konarka technologies

One or both of the outer layers may also be made of other materials that are flexible and preferably strong enough for architectural stretch film applications.

Optionally, one or both of the outer layers are coated with an Ultraviolet (UV) reflective film, a dye or scratch resistant film, or another suitable coating.

If additional outer and/or inner layers are employed, they may be made of materials such as those disclosed herein or other suitable materials.

It is also possible to use an arrangement using an insert fixed to one layer, for example by gluing. For example, an architectural membrane structure may consist of a single layer lined with an insert, or may include a layer having an insert secured thereto.

In many implementations of the present invention, the architectural membrane structure comprises an aerogel or another porous material, preferably a nanoporous material. In some examples, the material may be provided as a liner for one or both of the outer layers. In preferred embodiments, the material is present in an insert layer that may consist of, may consist essentially of, or may comprise aerogel and/or another porous material.

Aerogels are low density porous solids with large intra-particle pore volumes. Typically, they are made by removing pore liquid from a wet gel. However, the drying process can be complicated by capillary forces in the pores of the gel, which can cause the gel to shrink or densify. In one method of manufacture, collapse of the three-dimensional structure is substantially eliminated by using supercritical drying. The wet gel may also be dried using ambient pressure, which is also referred to as non-supercritical drying. Surface modification, e.g. capping, performed prior to drying prevents permanent shrinkage of the dried product when applied, e.g., to a silica-based wet gel. The gel is still able to shrink during drying but springs back to restore its previous porosity.

The product, called "xerogel", is also obtained from a wet gel from which the liquid has been removed. The term generally refers to a dry gel that is compressed by capillary forces during drying, characterized by permanent changes and collapse of the solid phase network.

For convenience, the term "aerogel" is used herein in a general sense to refer to both "aerogels" and "xerogels".

Aerogels generally have a low bulk density (about 0.15 g/cm)³Or less, preferably about 0.03 to 0.3g/cm³) Very high surface area (typically about 300 to about 1000 square meters per gram (m)²Per g) and higher, preferably from about 600 to about 1000m²Per gram), high porosity (about 90% and greater, preferably greater than about 95%), and relatively large pore volume (about 3 milliliters per gram (mL/g), preferably about 3.5mL/g and greater). Aerogels can have a nanoporous structure with pores less than 1 micrometer (μm). Typically, aerogels have an average pore diameter of about 20 nanometers (nm). The combination of these properties in the amorphous structure gives low thermal conductivity values (e.g., 9-16 (mW)/m.K at an average temperature of 37 ℃ and a pressure of 1 atmosphere). Aerogels can be nearly transparent or semi-transparentTransparent, scattering blue light, or may be opaque.

A common type of aerogel is silica-based. Aerogels based on oxides of metals other than silicon, such as aluminum, zirconium, titanium, hafnium, vanadium, yttrium and other metals, or mixtures thereof, may also be utilized.

Organic aerogels, such as resorcinol or melamine in combination with formaldehyde, dendrimers, etc., are also known and the invention can also be practiced using these materials.

Suitable aerogel materials and methods for their preparation are described, for example, in U.S. patent application No.2001/0034375Al, published by Schwertfeger et Al, 2001, 10/25, the teachings of which are incorporated herein by reference in their entirety.

The aerogel material employed can be hydrophobic. The terms "hydrophobic" and "hydrophobized" as used herein refer to partially and fully hydrophobized aerogels. The hydrophobicity of the partially hydrophobized aerogel can be further increased. In fully hydrophobized aerogels, the highest coverage is achieved and essentially all chemically available groups are modified.

Hydrophobicity can be determined by methods known in the art, such as contact angle measurement or by methanol (MeOH) wetting ability. A discussion of the hydrophobicity associated with aerogels is found in U.S. Pat. No.6,709,600B2 to Hrubesh et al, 3-23-2004, the teachings of which are incorporated herein by reference in their entirety.

Hydrophobic aerogels can be made by using: hydrophobizing agents such as silylating agents; halogen-containing and especially fluorine-containing compounds, such as fluorine-containing alkoxysilanes or alkoxysiloxanes, for example trifluoropropyltrimethoxysilane (TFPTMOS); and other hydrophobizing compounds known in the art. The hydrophobizing agent can be used during aerogel formation and/or in subsequent processing steps such as surface treatment.

Preferred are silylated compounds such as silanes, halosilanes, alkylhalosilanes, alkoxysilanes, alkoxyalkyl silanes, alkoxyhalosilanes, disiloxanes, disilazanes, and the like. Examples of suitable silylating agents include, but are not limited to, diethyldichlorosilane, allylmethyldichlorosilane, ethylphenyldichlorosilane, phenylethyldiethoxysilane, trimethylalkoxysilanes such as trimethylbutoxysilane, 3, 3, 3-trifluoropropylmethyldichlorosilane, symdiphenyltetramethyldisiloxane (symdiphenyltetramethyldimethylsiloxane), trivinyltrimethylcyclotrisiloxane, hexaethyldisiloxane, pentylmethyldichlorosilane, divinyldipropoxysilane, vinyldimethylchlorosilane, vinylmethyldichlorosilane, vinyldimethylmethoxysilane, trimethylchlorosilane, hexamethyldisiloxane, hexenylmethyldichlorosilane, hexenyldimethylchlorosilane, dimethylchlorosilane, dimethyldichlorosilane, mercaptopropylmethyldimethoxysilane, bis {3- (triethoxysilyl) propyl } tetrasulfide, Hexamethyldisilazane, and combinations thereof.

Aerogels can be in the form of granules, flakes, beads, powders, or other particles and have any particle size suitable for the desired application. For example, the particles can be about 0.01 micrometers (μm) to about 10.0 millimeters (mm) and preferably have an average particle size of 0.3 to 4.0 mm.

An example of a commercially available aerogel material in particulate form is sold under the trade name of Cabot Corporation, Billerica, MassachusettsThose provided.The particles have a high surface area, a porosity of greater than about 90% and are available in particle sizes of, for example, about 8 μm to about 10 mm.

Aerogels can also be fabricated in monolithic shapes, for example, into rigid, semi-flexible, or flexible structures, such as mat-like composites comprising fibers. Flexible or semi-flexible monoliths are preferred for use in the inserts described herein.

Whether in particulate or monolithic form, the aerogel can include one or more additives such as fibers, opacifiers, colored pigments, dyes, and mixtures thereof. For example, silica aerogels can be prepared containing additives such as fibers and/or one or more metals or compounds thereof. Specific examples include aluminum, tin, titanium, zirconium or other non-silicon metals, and oxides thereof. Non-limiting examples of opacifiers include carbon black, titanium dioxide, zirconium silicate, and mixtures thereof. The additives can be provided in any suitable amount, for example, depending on the desired properties and/or specific application.

Composites comprising fibers and aerogels (e.g., fiber reinforced aerogels) and optionally at least one binder can also be employed. The fibers may have any suitable structure. For example, the fibers may not have a structure (e.g., no tie fibers). The fibers may have a matrix structure or similar felt-like structure, which may be patterned or may be irregular and random. Preferred fiber-containing composites include composites formed from aerogel and fibers, wherein the fibers have a lofty (lofty) fibrous structure, the form of a batt, or the form of a steel wool pad. Examples of materials suitable for use in preparing lofty fibrous structures include glass fibers, organic polymer fibers, silica fibers, quartz fibers, organic resin-based fibers, carbon fibers, and the like. The material having a lofty, fibrous structure may be used alone or in combination with a second open cell material, such as an aerogel material. For example, a blanket (blanket) may have silica aerogel dispersed in a material having a lofty, fibrous structure.

Other composite materials suitable for forming the insert layer include at least one aerogel and at least one syntactic foam. The Aerogel may be coated to prevent polymer intrusion into the pores of the Aerogel, such as described, for example, in international publication No. wo2007047970 entitled Aerogel Based Composites, the teachings of which are incorporated herein by reference in their entirety.

In one specific example, the insert is or includes a ruptured aerogel monolith such as described in U.S. patent No.5,789,075 issued to Frank et al at 8/4 of 1998, the teachings of which are incorporated herein by reference in their entirety. Preferably, the cracks enclose the aerogel fragments connected by the fibers. The aerogel chips can have a thickness of 0.001mm³～1cm³Average volume of (d). In a composite, the aerogel chips have a size of 0.1mm³～30mm³Average volume of (d).

In another specific example, the insert is a composite material comprising an aerogel material, a binder, and at least one fibrous material, such as described in, for example, U.S. patent No.6,887,563 issued to Frank et al on 3/5/2005, the teachings of which are incorporated herein by reference in their entirety.

Other specific examples of aerogel-based inserts are fiber-web/aerogel composites comprising bicomponent fibers as described in U.S. patent No.5,786,059 issued to Frank et al at 28/7/1998, the teachings of which are incorporated herein by reference in their entirety. Such composites use at least one layer of a fiber web and aerogel particles, wherein the fiber web comprises at least one bicomponent fiber material having lower and higher melting regions, and the fibers of the web are bonded to each other not only with the aerogel particles but also through the lower melting regions of the fiber material. In some applications, the bicomponent fibers are manufactured fibers consisting of two firmly interconnected polymers with different chemical and/or physical structures and containing regions with different melting points, i.e. lower and higher melting regions.

As described in the above-incorporated U.S. patent No.5,786,059, the bicomponent fibers may have a core-sheath structure. The core of the fiber is a polymer, preferably a thermoplastic polymer, having a melting point higher than the melting point of the thermoplastic polymer forming the sheath. The bicomponent fibers are preferably polyester/copolyester bicomponent fibers. Bicomponent fiber variants consisting of polyester/polyolefins such as polyester/polyethylene, or polyester/co-polyolefin, or bicomponent fibers with elastomeric sheath polymers may also be used. Side-by-side bicomponent fibers may also be used.

The web may further comprise at least one simple fibrous material that becomes bonded to the lower melting zone of the bicomponent fiber during thermal consolidation. The simple fibers are organic polymer fibers, such as polyester, polyolefin and/or polyamide fibers, preferably polyester fibers. The cross-section of the fibers may be round, trilobal, pentalobal, octalobal, ribbon-like, christmas tree-like, dumbbell-like, or star-shaped. Similarly, hollow fibers may be used. The melting point of these simple fibers should be higher than the melting point of the lower melting region of the bicomponent fibers.

In further embodiments, the insert layer is in the form of an aerogel sheet or blanket. The sheet or blanket may include aerogel particles dispersed in fibers, for example. In other cases, the sheet or blanket comprises a fibrous batt through which a continuous aerogel is penetrated. The sheet or blanket may be made, for example, from a wet gel structure as described in U.S. patent application publication No.2005/0046086 a1, published 3.3.2005 and U.S. patent publication No.2005/0167891 a1, published 4.8.2005 to Lee et al, the teachings of which are incorporated herein by reference in their entirety.

The insert may also consist of, consist essentially of, or may contain a porous material other than aerogel. In particular examples, the material is an oxide of a microporous or preferably nanoporous metal such as silicon, aluminum, zirconium, titanium, hafnium, vanadium, yttrium, and the like, and/or mixtures thereof. The term "microporous" as used herein refers to a material having pores of about 1 micron and larger; the term "nanopore" refers to a material having pores of less than about 1 micron, preferably less than about 0.1 micron. Pore size can be determined by methods known in the art, such as mercury intrusion porosimetry or microscopy. Preferably, the pores are interconnected, thereby creating an open porosity.

Combinations of insulating materials, such as those described above, may also be employed. For example, the insert may comprise different types of aerogels, such as aerogels in particulate and/or monolithic form.

Aerogels can also be combined with non-aerogel materials, for example with: one or more conventional insulators such as gases like argon, air, carbon dioxide, vacuum; pearlite; fiber glass; silicon dioxide; an aluminosilicate; plastic; or other materials known in the construction industry. If translucency is important, the aerogel material can be combined with transparent or translucent non-aerogel materials, such as glass beads or microspheres, such as those commercially available from 3M corporation.

The non-aerogel materials can have a particle size suitable for the application. For example, a suitable particle size for the non-aerogel material can be about 0.05mm to about 4 mm.

The aerogel and non-aerogel materials can be blended in any ratio suitable for the application. Some factors that may be considered are cost requirements, insulating properties, light transmittance, and the role of the composite in the overall construction. Typically, the non-aerogel material can be present in the mixture in an amount of 0-99%. For example, the aerogel and non-aerogel materials can be blended in a ratio of 20: 80 to 80: 20, such as in a ratio of 60: 40, 50: 50, or 40: 60. Other ratios may be used.

Optionally, the material used to form the insert layer or insert, such as loose aerogel particles or other particulate materials, may be enclosed in a film or shell made of one or more polymers, such as nylon, polycarbonate, sheet metal, or other suitable materials, thereby forming a pillow, felt, bag, or the like. The material may also be present in a layer.

The size and shape of the insert layer is adjusted to meet construction and design specifications. In an illustrative example, the insert has a thickness of about 0.125 inches or more. Preferably, the insert has a thickness of about 25mm to about 200 mm.

In one aspect of the invention, the insert layer has less than about 0.5g/cm³Preferably less than about 0.3g/cm³And more preferably less than about 0.1g/cm³The density of (c). In another aspect of the invention, the insert has a void volume fraction of at least 10% and preferably at least 50%. In a specific example, the insert has a percent void volume of at least 90%.

In a preferred implementation, the insert has a light transmission of greater than 0% and it is preferably translucent. The term "translucent" as used herein refers to a light transmission (% T) of at least 0.5% when measured at visible wavelengths. Preferably, the insert material has a% T of at least 10% at a thickness of 0.25 inches. As an example, made ofAn insert made of a material and having a thickness of 25mm has a visible light transmission of about 53%, while an insert made of a material having a thickness of 25mm has a visible light transmission of about 53%An insert made with a thickness of 50mm has a visible light transmission of about 26%. In other aspects of the invention, the insulating material eliminates glare, allowing for a soft, deep distribution of sunlight. For example, byThe light transmission of the insulator may be referred to as being diffuse.

Preferably an insulator. The term "insulation" or "insulator" as used herein refers to thermal, acoustical or electrical insulating properties. In a preferred implementation, the insert combines two or more of the insulating properties.

In one example, the insert is a thermal insulator. In many implementations, the insert has an R value of at least 2, and more preferably 3 to 38. The "R value" is a well-known parameter describing building materials and is a measure of heat resistance to heat flow.

In another example, the interposer layer has a substantially constant thermal conductivity (K value) in a range of about 12 to about 30 (mW)/m-K at 37 ℃ and a pressure of one atmosphere. Also preferred are inserts whose thermal conductivity or k-value remains constant or preferably decreases with load or compression.

In yet another example, the insert is a sound insulator. For example,the aerogel particles reduce the speed of sound through the structure, thereby reducing noise, particularly in the low to medium frequency range of 40-500 Hz.

In yet another embodiment, the insert is an electrical insulator.

Hydrophobic inserts are preferred. More preferably, the insert has water and mold resistance. Suitable inserts may also be fire resistant or fire retardant.

The insert layer may be resilient and/or compressible. In some implementations of the invention, the insert material has an elastic compressibility, wherein application of pressure to a volume of compressible material causes the volume occupied by the compressible material to decrease, and wherein the volume of the compressible material increases after the pressure is released and preferably returns to a value substantially equal to that before the pressure is applied. Thus, when the compression is removed, the elastic response to the compression or "compression rebound" results in a recovery of the thickness of the insert, preferably the entire thickness of the insert.

In one example, the insert is compressible and has a compressive resiliency that allows the material to be securely held between the layers. The insert may be capable of withstanding pressures of 1psi or preferably 10psi or more preferably 100psi or even more preferably 1000psi without permanent damage or breakage. When placed under a compressive load, the insert may undergo volumetric compression to a second volume that is 5% to 80% less than its initial volume. When the load is reduced, the insert then springs back to a final volume that is substantially greater than the second volume. This behavior allows for systems in which the insert substantially fills the volume between the layers, even if the volume changes due to wind loading, creep, mechanical compression, or other external forces.

Materials such as those described above may be incorporated into structures or composites suitable for use in architectural membrane applications during the manufacture of the composites. Existing assemblies may also be refurbished or refurbished to contain materials such as aerogels either as is or off-site. For example, an existing architectural membrane may be lined with a monolithic aerogel blanket that is optionally supported by a layer as described above, such as a first or second layer, or by other means. The air-supported cushion or pillow may also be designed or retrofitted to include aerogels or other materials as described herein.

Several methods can be employed to manufacture the architectural membrane structure. In one example, monolithic structures such as aerogel blankets are introduced into the structure or composite by stacking or layering. For example, a monolithic insert can be placed on top of a bottom layer and then covered with a top layer. The material retained in the shell or casing, e.g. loose particles, can be introduced in a similar manner.

To make the composite material, it is also possible to arrange a material, for example an aerogel in monolithic or granular form, or as part of the composite material, in the interstitial space formed between the above-mentioned first and second layers. An assembly having multiple layers may contain the material in one, more than one, or all of the interstitial spaces. Particulate material, such as aerogel, can be added to one interstitial space, while a single piece of material, such as an aerogel blanket, can be provided to another interstitial space.

In one example, the structure is manufactured by: the particulate material is placed between the layers as an insert, for example by introducing the particulate material into the space defined by the two outer layers and then using mechanical means to tightly encapsulate the material between the layers. Methods that may be used to make the enclosure include mechanical compression, layer tensioning, vacuum sealing, or other methods. When the insert material is compressible and resilient, it will be held firmly in place without wrinkling, flow, or significant cracking. The level of volume compression at a pressure of 1 atmosphere may be 10% or more, preferably 25% or more, or even more preferably 40% or more when compared to the initial bulk density.

In particular implementations, the compression of the material is sufficient to withstand, overcome, or maintain the volume change in the interstitial space in the event of a volume change caused by wind, creep, mechanical forces, or any combination thereof.

In another example, aerogel or another suitable material is incorporated into an architectural membrane structure by techniques such as disclosed in U.S. patent No.6,598,283B2 issued to Rouanet et al on 29/7/2003, the teachings of which are incorporated herein by reference in their entirety. U.S. patent No.6,598,283B2 describes, for example, a method that includes providing a sealed first container (container) containing aerogel particles at a first air pressure that is less than atmospheric pressure. The unrestrained volume of the aerogel particles at a first air pressure is less than the unrestrained volume of the aerogel particles at a second air pressure that is greater than the first air pressure. The sealed first container is placed in a second container, e.g., a space between outer layers, and the sealed first container is breached at the second air pressure to equalize the air pressure between the first and second containers and increase the volume of the aerogel particles, thereby forming the insulation article.

The techniques described in U.S. patent application publication No.2006/0272727Al to Dinon et Al, published 2006, 12, 7, may also be suitable for incorporating the insert material into the structures disclosed herein. U.S. patent application publication No.2006/0272727 discloses an insulated pipe-in-pipe (pipe-pipe) assembly comprising: (a) at least one inner tube, (b) an outer tube disposed about the at least one inner tube, thereby creating an annular space between the outer tube and inner tube, (c) a porous, resilient, compressible material disposed in the annular space, and (d) a remainder of a container (remnants) previously placed in the annular space and previously having the compressible material held in the annular space at a volume less than the volume of the compressible material. Methods of making such insulated pipe-in-pipe assemblies are also described.

In a specific example, loose particulate material is used between the layers together with a binder material. The layer may tightly encapsulate the material as described above, or may loosely encapsulate the material. In a loose enclosure, the layers may be kept separated by air in a pillow-like fashion. In this case, the insert material may completely fill the interior region of the pillow or may partially fill that region, attached to one or more of the outer layers by an optional adhesive.

Other suitable methods may be used to introduce the particulate material into the air-supported structure, such as an air pillow or cushion. Furthermore, air-supported cushion or pillow structures may be formed using a single piece of material and/or a composite material, such as an aerogel blanket or the like.

To reduce and minimize settling and void formation, the space or interstitial volume between the outer layers may be "overfilled" or "overfilled". An over-packed system may have a density at least as high as the tap density. For aerogel particles, overfilling is for densities above the tap density. In systems filled with aerogel particles that are very light compared to a relatively heavy frame, the density can be significantly greater than the tap density, for example, from about 105% to about 115% -120% and higher of the tap density.

Optionally, moisture may be removed from the insert material before, during, or after the insert material is added to form the architectural membrane structure.

The manufacturing or production process may further include adhering two or more of the first layer, the interposer layer, and the second layer (i.e., the plurality of layers) to one another. Non-adhesive techniques may also be employed, resulting in at least two of the layers being non-adhesive. Specific methods of joining two or more of the layers together include sewing the layers together, laminating the layers together, powder bonding the layers together, or other suitable techniques. The layers may be directly connected, or they may be indirectly connected together through intervening materials.

Suitable techniques that may be used to make the architectural membrane structures of the present invention include, but are not limited to, lamination, bonding, sandwiching between two tensile layers, sewing, riveting, blowing in loose materials, wet processing into composite form, and the like.

The building composite of the present invention can be finished into panels. To complete the composite, the edges and/or corners of the composite structure may be sealed or clamped together. The edge conditions of panels using the composite material of the present invention are shown in fig. 2 and 3. Also shown in fig. 2 and 3 is a fastening system or device that can be used in combination with the composite material of the present invention.

For example, fig. 2 shows a fastening device comprising an edge latch (edge bar)40 for fixing a plate 42. The panel 42 comprises a composite material, such as described above, having the insert 16 and the outer layers 12 and 14, which are optionally sealed. The plate is provided with a string-like or beaded edge 52. Edge latches 40 grip the layers and may be secured to a support or surrounding member.

Another method of fastening a composite material, such as described above, is shown in fig. 3. A fastening device 60 for securing a panel 62 comprising a composite material with an insert 16 is shown in fig. 3. In this example, the composite includes an outer layer 64 of non-structural material and a single outer layer 66 of reinforcing fabric, and the panels are secured using string-like edges 72 and clips 74.

The fastening system depicted in fig. 2 and 3 may be made in whole or in part of aluminum or another suitable material. Fastening means other than those depicted in fig. 2 and 3 may also be employed.

The architectural membrane structure of the present invention can have a substantially constant thickness, for example, from about 0.25 inches to about 4 inches, preferably from about 0.375 inches to about 3 inches.

In a preferred implementation, the structure may have an "R" value of at least 2, preferably about 3 to 38, which is a measure of heat resistance to heat flow. The desired R value for the overall structure or composite is a value that is greater than the R value of the outer layer without the insert.

Preferably, the thermal insulation properties of the architectural membrane structure increase with load or compression. In a specific implementation, the structure has a thermal conductivity (k value) that remains constant, or preferably decreases with load and/or compression.

In some embodiments, the architectural membrane structure has a light transmission (% T), e.g., visible light transmission, of greater than 0%, e.g., at least about 0.25%, preferably at least about 0.5%, e.g., from about 0.5% to about 2%, more preferably at least 2%, e.g., from about 2% to 10%, and most preferably greater than about 10% and up to 80% or more. Also preferred are composite materials having a high light reflectance, for example a light reflectance of at least 60%, preferably at least 70% and more preferably 80% or higher. Suitable methods for measuring light transmittance and spectral reflectance are set forth in european standard EN 410 or ASTM E424.

The solar heat gain coefficient may be, for example, about 0.21 to 0.73.

The building structure is preferably provided with particular sound absorbing and diffusing properties and has improved performance in terms of OITC ratings (outdoor-indoor sound transmission ratings) in the range of 40-400 Hz.

In a preferred implementation, the architectural membrane structure comprises a load-bearing insulator, i.e. an insulator that retains or substantially retains one or more of its insulating properties under mechanical load, such as its thermal insulating properties.

In a specific example, the insert transfers load between the outer layers under conditions such as wind, where one layer, e.g. a membrane, resists pressure from one direction, i.e. into the composite material, and the other layer or membrane resists pressure from the same direction, i.e. out of the composite material. These pressures may be about 10 to 40 pounds per square foot (psf). The structure disclosed herein also preferably resists snow loading, wherein pressure typically occurs only on the top layer; these pressures may range from 20psf to over 100 psf.

In some implementations, one of the outer layers is partially and preferably entirely supported by the insert, or both of the outer layers are partially and preferably entirely supported by the insert.

In other examples of the invention, the architectural membrane structures disclosed herein have fire resistant properties and are preferably fire resistant. Moreover, the structure may have water resistance, weather resistance, and/or mold resistance.

The structure or composite may constitute a building element, a structural element, or may be used as both a building element and a structural element. The composite material of the invention can be used to manufacture pre-assembled modules, as with conventional architectural membranes.

In some implementations, the architectural membrane structure is an air-supported cushion or an air-supported pillow.

In further implementations, the structure or composite of the present invention is used as a tensile structure having a shape determined by the tension in the composite and the geometry of the support structure. Typically, the structure includes flexible elements (e.g., composites and cables), non-flexible elements (e.g., struts, braces, beams, rings, or arches), and anchors (e.g., supports and mounts). Preferably, when installed, the tensile layer is a base layer.

In addition to three-dimensional curves, the composite material of the present invention may be pre-tensioned, e.g., pre-tensioned to a pre-tension value calculated based on the expected load during the life cycle of the building structure or composite material. Preferably, the pretension is high enough to have a minimum tension in both directions under any possible conditions. If the pre-tension is too low, the composite may become prone to wind induced vibration. If the pre-tension is too high, the composite may require heavy and expensive support structures and/or foundations.

Shapes that may be used alone or in combination include co-curved shapes, such as spheres or domes; a reciprocal curved shape, such as a saddle; and the like. Thus, the composite material of the present invention may be installed or pre-manufactured in dome, cone, wave, co-curved, reciprocal curved, folded and other shapes.

The architectural membrane composites according to the present invention can be used in aesthetic or other structures in the design and construction of building envelopes, such as roofs, overhangs, canopies, tents and tent-like structures, walls, art displays, incorporated into airports, storage facilities, hangars, arenas, activity centers, sports or meeting venues, domes, greenhouses, residential or commercial buildings, manufacturing plants, museums, hotels, universities, railways, transit or subway stations, waiting areas, movie theaters, arenas, walkways between buildings, connecting joints in industrial facilities, and the like.

A building envelope comprising the composite material disclosed herein may be used as a substitute for, or in addition to, a building envelope employing an existing architectural membrane.

The architectural membrane structures disclosed herein can be used as cladding or can be incorporated into domes and other buildings, such as U.S. patent No.4,736,553 to Geiger at 12.4.1988; U.S. Pat. No.5,103,600 to Geiger and Campbell, 4/14/1992; U.S. patent No.5,261,193 issued to Wieber et al on 16.11.1993 and U.S. patent No.5,430,979 issued to Wieber et al on 11.7.1995; U.S. patent No.5,502,928 to Terry, 4.4.2.1996; U.S. Pat. No.6,282,842Bl to Simens at 9/4 of 2001 and many others. The architectural membrane structures disclosed herein may be an alternative to, or may be combined with, existing materials, such as the flexible composite described in U.S. patent No.7,153,792 to Sahlin et al, 12.2006, 26.d. The teachings of these patents are incorporated herein by reference in their entirety.

For example, a building 200 including walls 202 and 204 and a roof 206 is shown in fig. 4A and 4B. Composite materials such as those described herein are supported by the beam 208. Alternatively or additionally to the beam 208, other support means may be employed, such as cabling and/or by air pressure.

The engineering method of incorporating the composite materials disclosed herein into various building designs depends on the purpose of the enclosure, its function, shape, the properties sought, and other factors. These methods may be the same as or different from known methods involving existing architectural membranes or methods being developed.

Examples are described in U.S. patent No.5,502,928 issued to Terry at 2.4.1996 and U.S. patent No.4,736,553 issued to Geiger at 12.4.1988, the teachings of which are incorporated herein by reference in their entirety. Other examples are described for example below and may be obtained fromwww.geigerenginners.comThe publication of (1): (i) design Experience with Nonlinear testing Based Systems, d.campbell, d.chen and p.gossen p.e.: tents, Trussesand Tensegrity; (ii) membrane Designs and Structures in the world, edited by Kazuo Ishii; (iii) campbell et al, a Tensioned Fabric Roofs for "Tensegrity" Domes. These publications are incorporated herein by reference in their entirety.

While the present invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.

Claims (57)

1. An architectural membrane structure comprising aerogel.

2. The architectural membrane structure of claim 1, wherein the aerogel is present as an aerogel composite, monolith, or in particulate form.

3. The architectural membrane structure of claim 1, wherein the aerogel is present in a blanket, mat, or sheet.

4. The architectural membrane structure of claim 1, wherein the aerogel is present in a fiber-web/aerogel composite.

5. The architectural membrane structure of claim 1, wherein the structure has a substantially constant thickness.

6. The architectural membrane structure of claim 1, wherein the structure has a first layer, a second layer, and an insert layer comprising the aerogel between the first and second layers.

7. The architectural membrane structure of claim 6, wherein the insert layer has a thickness of at least 0.375 inch.

8. The architectural membrane structure of claim 6, comprising an additional outer or inner layer disposed in the insert layer.

9. The architectural membrane structure of claim 6, wherein at least one of the first and second layers is woven.

10. The architectural membrane structure of claim 6, wherein at least one of the first and second layers is non-woven.

11. The architectural membrane structure of claim 6, wherein at least one of the first and second layers comprises fiberglass, polyester, polytetrafluoroethylene, metal mesh, fiber batting, or any combination thereof.

12. The architectural membrane structure of claim 6, wherein at least one of the first and second layers is coated with polytetrafluoroethylene, vinyl, silicone, titanium dioxide, or any combination thereof.

13. The architectural membrane structure of claim 6, wherein the space defined by the first and second layers is substantially completely filled with the aerogel.

14. The architectural membrane structure of claim 6, wherein the space defined by the first and second layers is partially filled with the aerogel.

15. The architectural membrane structure of claim 6, wherein the first and second layers have the same thickness.

16. The architectural membrane structure of claim 6, wherein the first or second layer has a thickness of at least about 0.03 inches.

17. The architectural membrane structure of claim 6, wherein at least two of the first layer, the insert layer, and the second layer are adhered to one another.

18. The architectural membrane structure of claim 6, wherein at least two of the first layer, the insert layer, and the second layer are non-adherent to one another.

19. The architectural membrane structure of claim 6, having at least one edge or corner that is sealed or clamped.

20. The architectural membrane structure of claim 1, having a thermal insulation R-value of at least 2.

21. The architectural membrane structure of claim 1, having a% transmittance T greater than 0%.

22. The architectural membrane structure of claim 1, wherein the structure is a tensioned structure.

23. The architectural membrane structure of claim 22, wherein the aerogel is disposed between a first layer and a second layer, and only one of the layers is tensioned.

24. The architectural membrane structure of claim 1, wherein the aerogel is disposed between a first layer and a second layer and transfers load between the layers.

25. The architectural membrane structure of claim 1, wherein the aerogel is attached to a layer.

26. The architectural membrane structure of claim 1, wherein, when installed, the aerogel is compressed.

27. The architectural membrane structure of claim 26, wherein the compression is sufficient to withstand a volume change in the interstitial space, wherein the volume change is caused by wind, creep, mechanical force, or any combination thereof.

28. The architectural membrane structure of claim 1, wherein the aerogel has an elastic response to compression.

29. The architectural membrane structure of claim 1, wherein the aerogel is present in a layer having a thermal conductivity value that decreases with load or compression.

30. The architectural membrane structure of claim 1, wherein the composite has thermal insulation properties, electrical insulation properties, acoustical insulation properties, or any combination thereof.

31. The architectural membrane structure of claim 1, wherein the aerogel is present having a density of no greater than 0.5g/cm³In a layer of density (c).

32. The architectural membrane structure of claim 1, wherein the aerogel is present in a layer having a void volume of at least 50%.

33. An architectural or structural envelope comprising the architectural membrane structure of claim 1.

34. The enclosure of claim 33 further comprising at least one additional member selected from the group consisting of flexible members, non-flexible members, and anchoring members.

35. The enclosure of claim 33 wherein the enclosure is a roof, overhang, ceiling, wall, aesthetic or artistic structure.

36. The envelope of claim 33, wherein the aerogel substantially fills the space between the layers when subjected to volumetric compression and subsequently to volumetric expansion.

37. A building comprising the enclosure of claim 33.

38. The building of claim 37, wherein the building is an airport, storage facility, hangar, arena, activity center, sports arena, meeting place, dome, greenhouse, residential or commercial building, manufacturing plant, museum, hotel, railroad, bus or subway station, canopy, passageway, or university.

39. A system comprising a fastening device and the architectural membrane structure of claim 1.

40. An architectural membrane structure comprising a particulate material.

41. The architectural membrane structure of claim 40, having a thermal insulation R value of from 3 to 38.

42. The architectural membrane structure of claim 40, having a light transmittance% T of from about 0.25 to about 80%.

43. The architectural membrane structure of claim 40, having a reflectance of at least 80%.

44. An architectural membrane structure having a thermal conductivity that remains substantially constant or decreases with load or compression.

45. An architectural membrane structure comprising a substantially load-bearing insulator.

46. An architectural membrane structure comprising a first membrane layer, a second membrane layer, and a nanoporous material between the layers.

47. The architectural membrane structure of claim 46, wherein the nanoporous material is a monolith, a particulate material, or a nanoporous composite material.

48. The architectural membrane structure of claim 46, further comprising an adhesive material between said layers.

49. A method of making an architectural membrane structure includes securing an aerogel material between a first layer and a second layer.

50. The method of claim 49, wherein at least two of the first layer, the insert layer comprising the aerogel material, and the second layer are adhered to one another.

51. The method of claim 49, wherein at least two of the first layer, the insert layer comprising the aerogel material, and the second layer are laminated to one another.

52. The method of claim 49, further comprising sealing or clamping at least one edge or at least one corner of the architectural membrane structure.

53. The method of claim 49, wherein the aerogel material is in particulate form.

54. The method of claim 49, wherein the aerogel material is encapsulated in the spaces between the layers by mechanical compression, layer tensioning, vacuum sealing, or any combination thereof.

55. The method of claim 49, wherein the aerogel material is provided in at least one container disposed between the layers.

56. The method of claim 55, further comprising rupturing the container.

57. The method of claim 49, wherein the aerogel material is provided in a blanket, mat, or composite.