Architectural membrane structures and methods for producing them

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.

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/cm 3 . 
   
   
       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.