ARCHITECTURAL MEMBRANE STRUCTURES AND METHODS FOR PRODUCING THEM

• US 20080229704A1
• Filed: 03/21/2008
• Published: 09/25/2008
• Est. Priority Date: 03/23/2007
• Status: Abandoned Application

• Current Assignee: Cabot Corporation, Geiger Gossen Hamilton Campbell Engineers PC, Birdair, Inc. (Taiyo Kogyo Corporation)
• Original Assignee: Cabot Corporation, Geiger Gossen Hamilton Campbell Engineers PC, Birdair, Inc. (Taiyo Kogyo Corporation)
• Inventors: Kalkstein, Hobart C., Hamilton, Kris P., Augustyniak, Martin J.
• Application Number:
  US12/052,931
• Publication Number:
  US 20080229704A1
• Time in Patent Office: Days
• US Class Current: 52/782.1
• CPC Class Codes: B32B 15/02 Layer formed of wires, e.g. mesh
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/16 next to a particulate layer
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/102 synthetic resin or rubber layer being a foamed layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2264/12 Mixture of at least two particles made of different materials
• CPC Class Codes: B32B 2266/0285 Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
• CPC Class Codes: B32B 2266/045 : Metal
• CPC Class Codes: B32B 2266/057 : Silicon-containing material, e.g. glass
• CPC Class Codes: B32B 2266/102 : Nanopores, i.e. with average diameter smaller than 0.1 µm
• CPC Class Codes: B32B 2266/104 : Micropores, i.e. with average diameter in the range from 0.1 µm to 0.1 mm
• CPC Class Codes: B32B 2266/126 : Aerogel, i.e. a supercritically dried gel
• CPC Class Codes: B32B 2266/128 : Xerogel, i.e. an air dried gel
• CPC Class Codes: B32B 2307/102 : Insulating
• CPC Class Codes: B32B 2307/206 : Insulating
• CPC Class Codes: B32B 2307/304 : Insulating
• CPC Class Codes: B32B 2307/3065 : Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/4026 : within the layer by addition of a colorant, e.g. pigments, dyes
• CPC Class Codes: B32B 2307/414 : Translucent
• CPC Class Codes: B32B 2307/416 : Reflective
• CPC Class Codes: B32B 2307/51 : Elastic
• CPC Class Codes: B32B 2307/54 : Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/548 : Creep
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/71 : Resistive to light or to UV
• CPC Class Codes: B32B 2307/712 : Weather resistant
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/72 : Density
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof
• CPC Class Codes: B32B 2419/04 : Tiles for floors or walls
• CPC Class Codes: B32B 2419/06 : Roofs, roof membranes
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 3/06 : for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/18 : characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side B32B5/02 takes precedence
• CPC Class Codes: B32B 3/26 : characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/20 : foamed in situ
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 7/08 : by mechanical means
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/78 : Heat insulating elements E04B1/7662 takes precedence
• CPC Class Codes: E04B 7/105 : Grid-like structures
• CPC Class Codes: E04C 2/243 : one at least of the material being insulating
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04C 2/54 : Slab-like translucent elements floors for transmitting light E04B5/46; translucent or open-work ceilings E04B9/32, E04B9/34; translucent roof coverings E04D3/06, E04D3/28

Abstract

An architectural membrane structure preferably includes an aerogel material disposed, for example, between two outer layers. The aerogel can be in monolithic or granular form or can be present in an aerogel composite. A method for manufacturing an architectural membrane structure includes securing an insert, e.g., an aerogel blanket, composite or granular aerogel, between a first and second layer. The architectural membrane structure can be used as a tensioned panel in envelopes such as roofing, overhangs, canopies or in other architectural or structural fabric applications.

Claims

1. An architectural membrane structure comprising aerogel.

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

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

4. The architectural membrane 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 including the aerogel between said first and second layers.

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

8. The architectural membrane structure of claim 6, comprising additional outer layers or interior layers that are interspersed in the insert layer.

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

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

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

12. The architectural membrane structure of claim 6, wherein at least one of said 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 a space defined by said first and second layers is substantially completely filled by the aerogel.

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

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

16. The architectural membrane structure of claim 6, wherein the first layer or the 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 not adhered 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 % 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 said 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 a load between said layers.

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

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

27. The architectural membrane structure of claim 26, wherein the compression is sufficient to accommodate a volume change in a gap space and 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 insulating properties, electrical insulating properties, acoustical insulating properties or any combination thereof.

31. The architectural membrane structure of claim 1, wherein the aerogel is present in a layer having a density no greater than 0.5 g/cm³.

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 envelope of claim 33, further comprising at least one additional element selected from the group consisting of a flexible element, a non-flexible element, and an anchorage element.

35. The envelope of claim 33, wherein the envelope is a roof, overhang, canopy, wall, esthetic or artistic structure.

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

37. A construction comprising the envelope of claim 33.

38. The construction of claim 37, wherein the construction is an airport, storage facility, hangar, arena, activity center, sports venue, gathering venue, dome, green house, residential or commercial building, manufacturing facility, 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 granular material.

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

42. The architectural membrane structure of claim 40, having a % T in the range 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 essentially the same 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 said layers.

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

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

49. A method for manufacturing an architectural membrane structure, comprising securing an aerogel material between a first and second layer.

50. The method of claim 49, wherein at least two of the first layer, an insert layer containing 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, an insert layer containing 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 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 enclosed in a space between said 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 placed between said layers.

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

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