CN101680222A - 建筑膜结构体及其制造方法 - Google Patents
建筑膜结构体及其制造方法 Download PDFInfo
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- CN101680222A CN101680222A CN200880016535A CN200880016535A CN101680222A CN 101680222 A CN101680222 A CN 101680222A CN 200880016535 A CN200880016535 A CN 200880016535A CN 200880016535 A CN200880016535 A CN 200880016535A CN 101680222 A CN101680222 A CN 101680222A
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- membrane structure
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- architectural membrane
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- floor
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Abstract
建筑膜结构体优选包括设置于例如两个外层之间的气凝胶材料。所述气凝胶可以为单块或粒状形式或者可以存在于气凝胶复合材料中。制造建筑膜结构体的方法包括将插入物例如气凝胶毯、复合材料或粒状气凝胶固定在第一和第二层之间。所述建筑膜结构体可用作围护例如屋顶、悬挑、天棚中或者其它建筑或结构织物应用中的张拉板。
Description
相关申请
本申请要求2007年3月23日提交的美国临时申请No.60/896,664、2007年3月24日提交的美国临时申请No.60/896,904、和2007年3月26日提交的美国临时申请No.60/908,057的优先权。将这些申请的教导全部引入本文作为参考。
背景技术
建筑膜,也称作张力或张拉结构体,正越来越多地用于建造机场、储存设施、竞技场、活动中心、运动或集会场地、穹顶、博物馆、房屋等。建筑膜在屋顶(roofing)、天棚、悬挑(overhang)和其它围护(envelope)结构体中提供了极大的设计灵活性。它们可常规地制成各种形状。还可利用预组装的模块。
引入了建筑膜的现有设计的实例包括加拿大卡尔加里的TalismanCenter、英国的Millennium Dome、丹佛国际机场、气承式屋顶例如在印第安纳波利斯RCA dome中使用的屋顶、以及许多其它实例。
可以使用已知的技术、规范和工业标准,例如由美国测试和材料协会(ASTM)提出的那些来表征建筑膜的照明、能量、耐久性或声学性质、以及耐火性能。例如,可使用ASTM E424确定透光率和光谱反射率;可使用ASTME-90确定声学性质;且可使用ASTM E-108或ASTM E-84确定防火性能。
现有的建筑膜包括由Saint-Gobain Corporation提供的已知名称为的那些。通常,建筑膜是基于纺织的涂布的玻璃纤维织物。在实际的安装中,建筑膜经常与一种或多种设计用于例如使声学干扰最小化的额外衬里一起使用。例如,在可得自www.birdair.com的Birdair′s Technical Specification & Fabric Characteristics中描述了若干类型的建筑膜的特征,将其教导全部引入本文作为参考。
通常,基于建筑膜的围护比永久性结构体轻,可以更容易地安装和拆除,并趋向于耐得住破坏力例如地震。
建筑膜的设计通常考虑一些与在设计常规建筑物时所考虑的标准相同的标准,例如基本负荷、风压和其它标准。这样的标准由具有管辖权的地方建筑法规或样板规范规定。另外,设计方法还可以包括涉及膜的张力几何结构、形状产生、双轴性能、应力和结构分析等的原理。
随着对节约能源和“绿色”建筑材料及实践的日益增长的需求,仍存在对这样的轻质建筑膜的需要,其在通常使用其的设计和应用中保持灵活性并仍提供改善的透光率和良好的热绝缘。还存在对具有改善的声学性质和高的反射率例如UV反射率性质的系统的需要。
发明内容
本发明总体上涉及可用于建筑和/或结构织物应用中的结构体。本发明的许多优选方面涉及包括具有绝缘或透光性质,并优选具有绝缘和透光性质两者的材料的建筑膜结构体。
可引入到本发明的建筑膜结构体中的材料包括气凝胶和其它材料,例如多孔如微孔或纳米孔(nanoporous)材料。在具体实例中,所述材料是粒状的。在其它实例中,所述材料是单块(monolith)或是复合材料。在另外的其它实例中,所述材料具有基本上保持不变并且优选随着负荷和/或压缩而下降的热导率(k值)。在进一步的实例中,所述结构体包括承重绝缘体。
在本发明的具体实施中,所述建筑膜结构体为多层结构体。例如,所述结构体包括:第一层,第二层,以及在所述第一层和第二层之间的材料例如单块气凝胶或颗粒气凝胶、或者气凝胶复合材料。还可以采用其中气凝胶或另外的合适材料粘附或以其它方式固定于单一的层上的布置。
本发明的方面还涉及具有基本上保持不变或随着负荷和/或压缩而减小的热导率或k值的建筑膜结构体。
在许多实施中,本发明的建筑膜具有如下性质中的一种或多种:大于0.25%,优选大于0.5%,且最高达0.80%和更高的透光率;至少60%,优选至少70%,更优选80%和更高的反射率;至少0.05的太阳得热系数;3~38的R值;和/或如下进一步所述的其它性质。
本发明的实施方式还涉及制造建筑膜结构体的方法。在一个实例中,所述方法包括将气凝胶材料固定在第一层和第二层之间。
本发明的实施方式可以用在建筑或结构围护例如屋顶、顶篷、墙、悬挑、气承式结构体如气垫或气枕、以及其它建筑元件中,其中本文公开的结构体可以替代由柔性的、涂布的或层压的结构织物或膜制成的现有建筑膜并且可以满足强加的负荷要求并将该负荷传递至支承元件。
与常规的建筑膜一样,本发明的结构体是轻质的,具有适合用于织物结构体技术的张力性质并且可支承相当大的量的积雪。其可以设计用于各种形状和应用并可以具有良好的耐久性和耐火性。在许多情况下,所述结构体是半透明的,从而降低了对室内照明的需要或者使对室内照明的需要最小化。其优选具有良好的绝缘性质并可以有助于减少供热和/或制冷的需求和成本。在一些实施方式中,本发明使得利用比现有绝缘系统更轻、更加半透明的织物元件以获得相同的总的强度并且成本更低成为可能。
附图说明
在附图中,在不同的视图中各标记符号始终表示相同的部件。附图不一定是按照比例绘制的,而是将重点放在了说明本发明的原理上。在附图中:
图1是本发明的建筑或结构复合材料的横截面图,其显示了外层与插入物层或内层。
图2是包括固定本发明的建筑或结构复合材料的紧固系统的装置的横截面图。
图3是包括固定本发明的建筑或结构复合材料的另一种紧固系统的另一装置的横截面图。
图4A是包括可以采用本发明复合材料的屋顶的建筑物的横截面侧视图。
图4B是图4A中所示建筑物的俯视图。
具体实施方式
本发明的包括部件的构造和组合的各种细节的以上和其它特征、以及其它优势现在将通过参考附图得以更具体地描述并在权利要求中指出。应该理解,体现本发明的特定方法和设备通过说明的方式示出并且不限制本发明。本发明的原理和特征可用于许多不同的实施方式中而不脱离本发明的范围。
本发明总体上涉及建筑和/或结构元件,更具体地说涉及“织物结构体”,其在本文中也称作“建筑膜结构体”、“建筑结构体”或简单地称作“结构体”或“复合材料”,最后两个术语可互换使用。在许多实施方式中,本发明涉及柔性的且多层(即具有两个或更多个层)的建筑结构体。
在一些方面中,所述结构体是通常仅负载拉伸应力而没有压缩或弯曲的张拉或张力结构体。在具体的实例中,本文中公开的结构体满足所提议的在膜的平面中仅负载张力或剪切力的工业标准。
在其它方面中,所述结构体可用作在结构织物应用例如张力膜、气承式建筑膜、气垫或气枕、折叠膜、张拉整体支承膜、以桁架和穹顶支承的柔性包层、建筑立面、屋顶、建筑物围护等中采用的现有建筑膜的替代物。现有的建筑织物可分为永久性结构体或可移动结构体,并且本文中公开的复合材料可与这两种结构体组合使用或者作为这两种结构体的替代物。
在本发明的具体实施中,复合材料或结构体包括第一层、第二层(这些层在本文中也称作“外层”)和在所述第一层和第二层之间的内层(在本文中也称作“插入物层”或“插入物”)。例如,图1中示出了包括外层12和14以及夹在其间的插入物16的三层结构体10。关于实际的围护安装,所述外层可以指底层和顶层,其中所述顶层从该建筑结构体的内部面向外面。外层之一可以或外层中的两个都可以设置有一层或多层衬里或涂层。在安装时,可以对一个层进行张拉或对两个层都进行张拉。
可采用额外的层和/或插入物。例如,可以在第一层上堆叠第一插入物并且用第二层覆盖该第一插入物,该第二层又支承第二插入物,该第二插入物覆盖有另外的层,在其上设置有任选的插入物和更多的层,其中该另外的层具有任选的插入物。
在本发明的一些方面中,一个或多个内层(未在图1中示出)可存在于例如配置于所述插入物中。在其它方面中,至少一个额外的外层(也未在图1中示出)分别设置于顶层之上或底层之下。
这些层可用于改善在总的结构体中所需的性质,例如提高总的强度,提高耐磨性,提供合意的声学、日光和/或光性质。内层和/或额外的外层可以贯穿所述结构体的整个表面或者可以设置在特定区域中。
外层可以相同或不同。可采用现有的织物或建筑膜,或者其层。外层之一可以是或外层中的两个都可以是增强织物膜。还可以使用非结构性的外层。外层之一可以或外层中的两个都可以包括衬里或者其自身可以是复合材料。用于气承式结构体中的膜还可以用作外层之一或两者。
对外层的尺寸和形状进行调整以满足施工和设计规格,外层可具有相同或不同的厚度。所述层厚度可为例如至少约0.10毫米(mm)并最高达约60mm。通常,所述层具有约22mm~约40mm的厚度。
在一个实例中,外层之一包括纺织材料或外层中的两个都包括纺织材料。在另一实例中,外层之一是无纺的或者外层中的两个都是无纺的。
在本发明的优选方面中,外层中的至少一个层是半透明的,并优选外层中的两个层都是半透明的。优选具有结构上的耐受性、耐火性、耐UV性、抗霉性、耐水性和/或耐候性的外层。
可用于制造外层之一或两者的材料包括但不限于玻璃纤维、网孔材料例如金属网、纤维棉胎(fibrous batting)、芳族聚酰胺、烯烃、尼龙、丙烯酸类树脂、聚酯、天然纤维例如棉花、卤代聚合物例如聚四氟乙烯(PTFE)(其可例如以商品名得到)等、以及材料的组合。还可以使用薄片(foil),例如由乙烯-四氟乙烯(ETFE)制成的那些,其可例如以牌号得自Dupont。
不论是纺织的还是无纺的,所述第一和/或第二层都可涂布有PTFE、乙烯基树脂例如聚氯乙烯(PVC)、硅树脂(silicone)、聚氨酯、丙烯酸类树脂、二氧化钛(TiO2)、其它材料或其组合。所述涂层可通过涂抹、浸渍、喷涂、气相沉积技术、层压或本领域中已知的其它方法施加。
在一个实施方式中,外层中的至少一个层是由可得自Saint-GobainCorporation的膜材料制造的,且优选外层中的两个层都是由可得自Saint-Gobain Corporation的膜材料制造的。可使用的其它市售的PTFE涂布的玻璃纤维膜包括Taconic International Ltd.的膜、VerseidagSeemee US Inc.的或Chukoh ChemicalIndustries LTD的PTFE涂布的玻璃纤维膜。适合的还有膨胀的纺织PTFE(ePTFE)膜,例如W.L.GoreAssoc.Inc.的商品名为的那些。
可利用的市售的硅树脂涂布的玻璃纤维膜包括Fabrimax的Interglas的和Ferrari Textiles的300。硅树脂涂布的聚酯膜是由PD Interglas开发的那些。溶液染色的聚酯膜是市售的得自Safety ComponentsFabric Technologies Inc的Weatherman或者得自Glen Raven CustomFabrics L.L.C的Fireset
基于烯烃的膜包括已知的得自Enginecrcd Coatcd Products的名为Nova-得自Inter Wrap的名为和得自Synthesis Fabrics的名为的那些。烯烃稀松组织锁缝编织网(olefin open weave lock-knitmesh)的实例包括Solarfab Inc.的和Gale Pacific的纺织聚偏二氟乙烯(PVDF)是可从Duckers & Friends以牌号商购得到的。
可用于形成所述第一层和/或第二层的市售的丙烯酸类树脂涂布的聚酯包括John Boyle的MainGraniteville Specialty Fabrics的和Marchem coated Fabrics Inc的
外层之一还可以或外层中的两个层都还可以由柔性的并优选对于建筑拉伸膜应用足够强的其它材料制成。
任选地,外层之一涂覆有或者外层中的两个层都涂覆有紫外(UV)反射膜、染料或防划痕膜、或者另外的合适的涂层。
如果采用额外的外层和/或内层,则它们可以由例如本文公开的材料或由其它合适的材料制成。
还可以采用这样的布置,该布置使用例如通过粘合而固定至一个层上的插入物。例如,建筑膜结构体可由加上插入物作为衬里的单层组成,或者可包括具有固定到其上的插入物的层。
在本发明的许多实施中,所述建筑膜结构体包括气凝胶或另外的多孔材料,优选纳米孔材料。在一些实例中,所述材料可设置为外层之一或两者的衬里。在优选的实施方式中,所述材料存在于可由气凝胶和/或另外的多孔材料组成、可基本上由气凝胶和/或另外的多孔材料组成、或者可包含气凝胶和/或另外的多孔材料的插入物层中。
气凝胶是具有大的颗粒内孔体积的低密度多孔固体。通常,它们通过从湿凝胶中除去孔液体而制造。然而,凝胶孔中的毛细管力可使干燥过程复杂化,所述毛细管力可以导致凝胶收缩或致密化。在一种制造方法中,通过使用超临界干燥基本上消除了该三维结构的坍塌。还可以使用环境压力干燥湿凝胶,这也称为非超临界干燥法。当例如应用于基于二氧化硅的湿凝胶时,在干燥前进行的表面改性例如封端防止了干燥产物的永久性收缩。所述凝胶在干燥期间仍然能够收缩,但会弹回从而恢复其之前的孔隙率。
称作“干凝胶”的产物也由已经除去了液体的湿凝胶获得。该术语通常是指在干燥期间通过毛细管力压缩的干的凝胶,其特征在于固相网络的永久性改变和坍塌。
为了方便起见,术语“气凝胶”以笼统的意义用于本文中,其指“气凝胶”和“干凝胶”两者。
气凝胶通常具有低的堆密度(bulk density)(约0.15g/cm3或更低,优选为约0.03~0.3g/cm3)、非常高的表面积(通常为约300~约1000平方米每克(m2/g)和更高,优选为约600~约1000m2/g)、高的孔隙率(约90%和更大,优选大于约95%)、和相对大的孔体积(约3毫升每克(mL/g),优选为约3.5mL/g和更高)。气凝胶可具有孔小于1微米(μm)的纳米孔结构。通常,气凝胶具有约20纳米(nm)的平均孔直径。无定形结构中这些性质的组合给出了低的热导率值(例如在37℃的平均温度和1个大气压的压力下为9~16(mW)/m·K)。气凝胶可以是几乎透明的或半透明的,散射蓝光,或者可以是不透明的。
气凝胶的常用类型是基于二氧化硅的。还可以利用基于除硅之外的金属例如铝、锆、钛、铪、钒、钇和其它金属的氧化物或其混合物的气凝胶。
还已知有机气凝胶,例如与甲醛组合的间苯二酚或三聚氰胺、树枝状聚合物等,并且本发明还可以使用这些材料进行实施。
合适的气凝胶材料及其制备方法描述于例如Schwertfeger等人于2001年10月25日公开的美国专利申请No.2001/0034375Al中,其教导全部引入本文作为参考。
采用的气凝胶材料可以是疏水的。本文中使用的术语“疏水”和“疏水化”是指部分和完全疏水化的气凝胶。部分疏水化的气凝胶的疏水性可进一步增加。在完全疏水化的气凝胶中,达到最高的覆盖率并且基本上所有可通过化学方式获得的基团被改性。
疏水性可通过本领域中已知的方法例如接触角测量或通过甲醇(MeOH)润湿能力测定。与气凝胶相关的疏水性的讨论参见2004年3月23日授权给Hrubesh等人的美国专利No.6,709,600B2中,其教导全部引入本文作为参考。
疏水气凝胶可通过使用如下物质制造:疏水化试剂例如甲硅烷基化剂;含卤素且尤其是含氟的化合物,例如含氟的烷氧基硅烷或烷氧基硅氧烷例如三氟丙基三甲氧基硅烷(TFPTMOS);和本领域中已知的其它疏水化化合物。疏水化试剂可以在气凝胶形成期间和/或在后续加工步骤例如表面处理中使用。
优选甲硅烷基化化合物例如硅烷、卤代硅烷、烷基卤代硅烷、烷氧基硅烷、烷氧基烷基硅烷、烷氧基卤代硅烷、二硅氧烷、二硅氮烷等。合适的甲硅烷基化剂的实例包括,但不限于二乙基二氯硅烷、烯丙基甲基二氯硅烷、乙基苯基二氯硅烷、苯基乙基二乙氧基硅烷、三甲基烷氧基硅烷例如三甲基丁氧基硅烷、3,3,3-三氟丙基甲基二氯硅烷、对称二苯基四甲基二硅氧烷(symdiphenyltetramethyldisiloxane)、三乙烯基三甲基环三硅氧烷、六乙基二硅氧烷、戊基甲基二氯硅烷、二乙烯基二丙氧基硅烷、乙烯基二甲基氯硅烷、乙烯基甲基二氯硅烷、乙烯基二甲基甲氧基硅烷、三甲基氯硅烷、六甲基二硅氧烷、己烯基甲基二氯硅烷、己烯基二甲基氯硅烷、二甲基氯硅烷、二甲基二氯硅烷、巯丙基甲基二甲氧基硅烷、二{3-(三乙氧基甲硅烷基)丙基}四硫化物、六甲基二硅氮烷、及其组合。
气凝胶可以是粒状、片、珠、粉末、或其它颗粒的形式并具有适于期望应用的任意粒度。例如,所述颗粒可为约0.01微米(μm)~约10.0毫米(mm)并优选具有0.3~4.0mm的平均粒度。
颗粒形式的市售气凝胶材料的实例是由Cabot Corporation,Billerica,Massachusetts以商品名提供的那些。颗粒具有高的表面积,大于约90%的孔隙率并且其可以例如约8μm~约10mm的粒度获得。
气凝胶还可以单块形状制造成例如刚性、半刚性、半柔性或柔性结构,例如包括纤维的毡(mat)状复合材料。柔性或半柔性的单块优选用在本文所述的插入物中。
不论是颗粒形状还是单块形状,所述气凝胶都可包括一种或多种添加剂例如纤维、遮光剂、着色颜料、染料、及其混合物。例如,二氧化硅气凝胶可制备为含有添加剂例如纤维和/或一种或多种金属或其化合物。具体实例包括铝、锡、钛、锆或其它非硅金属、及其氧化物。遮光剂的非限制性实例包括炭黑、二氧化钛、硅酸锆、及其混合物。添加剂可以任意合适的量提供,该量例如取决于期望的性质和/或具体应用。
还可以采用包含纤维和气凝胶(例如纤维增强气凝胶)和任选的至少一种粘合剂的复合材料。所述纤维可具有任意合适的结构。例如,所述纤维可以不具有结构(例如,无连系的纤维)。所述纤维可具有矩阵(matrix)结构或类似的毡状结构,其可以被图案化或者可以是不规则的和无规的。优选的包含纤维的复合材料包括由气凝胶和纤维形成的复合材料,其中所述纤维具有膨松有弹性的(lofty)纤维状结构、棉胎的形式或者类似于钢棉垫的形式。适合用于制备膨松有弹性的纤维状结构的材料的实例包括玻璃纤维、有机聚合物纤维、二氧化硅纤维、石英纤维、基于有机树脂的纤维、碳纤维等。具有膨松有弹性的纤维状结构的材料可单独使用或者与第二开孔材料例如气凝胶材料组合使用。例如,毯(blanket)可具有分散在具有膨松有弹性的纤维状结构的材料中的二氧化硅气凝胶。
适于形成插入物层的其它复合材料包含至少一种气凝胶和至少一种复合泡沫塑料。可以像例如题为Aerogel Based Composites的国际公布No.WO2007047970中描述的那样对所述气凝胶进行涂覆以防止聚合物侵入到所述气凝胶的孔中,将其教导全部引入本文作为参考。
在一个具体的实例中,所述插入物为或者包括例如1998年8月4日授权给Frank等人的美国专利No.5,789,075中所描述的破裂的气凝胶单块,将该专利的教导全部引入本文作为参考。优选地,裂缝围住通过纤维连接的气凝胶碎片。气凝胶碎片可具有0.001mm3~1cm3的平均体积。在一种复合材料中,所述气凝胶碎片具有0.1mm3~30mm3的平均体积。
在另一具体实例中,所述插入物为像例如2005年5月3日授权给Frank等人的美国专利No.6,887,563中所述的包含气凝胶材料、粘合剂和至少一种纤维材料的复合材料,将该专利的教导全部引入本文作为参考。
基于气凝胶的插入物的其它具体实例为如1998年7月28日授权给Frank等人的美国专利No.5,786,059中所述的包含双组分纤维的纤维-网(fiber-web)/气凝胶复合材料,将该专利的教导全部引入本文作为参考。这样的复合材料使用至少一个纤维网和气凝胶颗粒的层,其中所述纤维网包括至少一种双组分纤维材料,所述双组分纤维材料具有较低和较高的熔融区,并且所述网的纤维不仅与所述气凝胶颗粒结合而且还通过所述纤维材料的较低熔融区彼此结合。在一些应用中,所述双组分纤维是制造的纤维,其由两种具有不同化学和/或物理结构的牢固地相互连接的聚合物组成并且包含具有不同熔点的区域,即较低和较高熔融区。
如以上引入的美国专利No.5,786,059中所述,双组分纤维可具有芯-皮结构。所述纤维的芯为聚合物,优选热塑性聚合物,其熔点高于形成皮的热塑性聚合物的熔点。所述双组分纤维优选为聚酯/共聚酯双组分纤维。还可使用由聚酯/聚烯烃例如聚酯/聚乙烯、或聚酯/共聚烯烃组成的双组分纤维变体或者具有弹性皮聚合物的双组分纤维。还可采用并列型双组分纤维。
所述纤维网可进一步包含至少一种简单的纤维材料,其在热固结期间变成与所述双组分纤维的较低熔融区结合。所述简单纤维是有机聚合物纤维,例如聚酯、聚烯烃和/或聚酰胺纤维,优选聚酯纤维。所述纤维的横截面可以是圆形、三叶形、五叶形、八叶形、带状、类似圣诞树、哑铃形状或者星形。类似地,可以使用中空纤维。这些简单纤维的熔点应该高于所述双组分纤维的较低熔融区的熔点。
在进一步的具体实例中,所述插入物层为气凝胶片或毯的形式。所述片或毯可包括例如分散在纤维中的气凝胶颗粒。在其它情况下,所述片或毯包含贯穿有连续的气凝胶的纤维棉胎。片或毯可以由例如湿凝胶结构制造,所述湿凝胶结构描述于Lee等人的2005年3月3日公布的美国专利申请公布No.2005/0046086 A1和2005年8月4日公布的美国专利公布No.2005/0167891 A1中,其教导全部引入本文作为参考。
所述插入物还可以由除气凝胶之外的多孔材料组成、基本上由除气凝胶之外的多孔材料组成、或者可以包含除气凝胶之外的多孔材料。在具体实例中,所述材料为微孔的或者优选纳米孔的金属例如硅、铝、锆、钛、铪、钒、钇等的氧化物和/或它们的混合物。本文中使用的术语“微孔的”是指具有约1微米和更大的孔的材料;术语“纳米孔”是指具有小于约1微米,优选小于约0.1微米的孔的材料。孔尺寸可通过本领域中已知的方法例如压汞孔隙率测定法或显微镜法确定。优选地,所述孔是相互连接的,从而产生开放型的多孔性。
还可以采用例如如上所述的绝缘材料的组合。例如,所述插入物可包含不同类型的气凝胶,例如颗粒和/或单块形式的气凝胶。
气凝胶还可以与非气凝胶材料组合,例如与如下材料组合:一种或多种常规的绝缘体例如气体如氩气、空气、二氧化碳、真空;珠光体;纤维玻璃;二氧化硅;硅铝酸盐;塑料;或建筑工业中已知的其它材料。如果半透明性是重要的,则气凝胶材料可以与透明或半透明的非气凝胶材料组合,所述透明或半透明的非气凝胶材料例如为玻璃微珠或微球,例如可从3MCorporation商购得到的那些。
非气凝胶材料可具有适于该应用的粒度。例如,非气凝胶材料的合适粒度可为约0.05mm~约4mm。
气凝胶和非气凝胶材料能够以适于该应用的任何比例共混。可以考虑的一些因素是成本要求、绝缘性质、透光率、以及复合材料在总的建筑中的作用。通常,非气凝胶材料在混合物中的存在量可为0~99%。例如,气凝胶和非气凝胶材料能够以20∶80~80∶20的比率共混,例如以60∶40、50∶50或40∶60的比率共混。可以使用其它比率。
任选地,用于形成插入物层或插入物的材料例如疏松的气凝胶颗粒或其它粒状材料可以被包封在由一种或多种聚合物例如尼龙、聚碳酸酯、金属片、或其它合适的材料制成的膜或外壳中,由此形成枕、毡、袋等。所述材料还可以存在于层中。
调整插入物层的尺寸和形状以满足施工和设计规格。在说明性的实例中,所述插入物具有约0.125英寸或更大的厚度。优选地,所述插入物具有约25mm~约200mm的厚度。
在本发明的一个方面中,所述插入物层具有小于约0.5g/cm3,优选小于约0.3g/cm3且更优选小于约0.1g/cm3的密度。在本发明的另一方面中,所述插入物具有至少10%且优选至少50%的空隙体积分数。在具体的实例中,所述插入物具有至少90%的空隙体积百分率。
在优选的实施中,所述插入物具有大于0%的透光率且其优选是半透明的。本文中使用的术语“半透明的”是指当在可见光波长下测量时至少为0.5%的透光率(%T)。优选地,所述插入物材料在0.25英寸的厚度下具有至少10%的%T。作为一个实例,由材料制成并具有25mm厚度的插入物具有约53%的可见光透射率,而由制成并具有50mm厚度的插入物具有约26%的可见光透射率。在本发明的其它方面中,绝缘材料消除了眩光,从而允许日光的柔和的、深的分布。例如,通过绝缘体的光透射可以称为是散射的。
优选是绝缘体的插入物层。本文中使用的术语“绝缘”或“绝缘体”是指热绝缘、隔音或电绝缘性质。在优选的实施中,所述插入物结合了绝缘性质中的两种或更多种。
在一个实例中,所述插入物为热绝缘体。在许多实施中,所述插入物具有至少为2,更优选为3~38的R值。“R值”是描述建筑材料的公知的参数并且是对热流的耐热性的度量。
在另一实例中,所述插入物层在37℃和一个大气压的压力下具有在约12~约30(mW)/m·K范围内的基本上恒定的热导率(k值)。还优选其热导率或k值保持恒定或者优选随着负荷或压缩而减小的插入物。
在又一实施例中,所述插入物为电绝缘体。
优选疏水的插入物。更优选具有耐水性和耐霉性的插入物。合适的插入物还可具有耐火性或防火性。
所述插入物层可为具有回弹性的和/或为可压缩的。在本发明的一些实施中,所述插入材料具有弹性的压缩性,其中对大量的可压缩材料施加压力导致该可压缩材料所占据的体积减小,并且其中在释放压力之后所述可压缩材料的体积增加并优选返回至与施加压力之前基本上相等的值。因此,当除去压缩时,对压缩的弹性响应或者“压缩回弹”导致插入物厚度的恢复,优选插入物整个厚度的恢复。
在一个实例中,所述插入物是可压缩的并且具有容许该材料牢固地保持在层间的压缩回弹力。所述插入物可能够承受1psi或优选10psi或更优选100psi或更进一步优选1000psi的压力而没有永久性损坏或破坏。当将插入物置于压缩负荷下时,所述插入物可经历体积压缩至比其初始体积小5%~80%的第二体积。当减小负荷时,所述插入物则弹回至显著大于所述第二体积的最终体积。该行为容许这样的系统,其中插入物基本上填充层间的体积,即使所述体积因风力荷载、蠕变、机械压缩或其它外力而改变也是如此。
可以在制造复合材料期间将例如上述的材料引入到适合用于建筑膜应用的结构体或复合材料中。现有组件还可以进行再刷新或翻新以原为或离位包含例如气凝胶的材料。例如,现有建筑膜可以加上单块气凝胶毯为衬里,该单块气凝胶毯任选地被如上所述的层例如第一或第二层支承或者通过其它方式支承。气承式垫或气承式枕还可以设计或翻新为包含本文所述的气凝胶或其它材料。
可采用若干方法来制造建筑膜结构体。在一个实例中,通过堆叠或分层堆积将单块结构体例如气凝胶毯引入到所述结构体或复合材料中。例如,可将单块插入物置于底层之上,然后用顶层覆盖该单块插入物。可以类似的方式引入保留在壳层或外壳中的材料例如疏松的颗粒。
为了制造复合材料,还可以将材料例如单块或粒状形式的气凝胶,或者将该材料作为复合材料的一部分,设置于在上述第一层与第二层之间形成的间隙空间中。具有多个层的组件可以在一个、多于一个、或者所有的间隙空间中含有所述材料。可以将颗粒材料例如气凝胶加入到一个间隙空间中,同时可以将单块材料例如气凝胶毯提供到另一间隙空间中。
在一个实例中,所述结构体通过如下制造:将颗粒材料作为插入物置于各层之间,例如将颗粒材料引入到由两个外层所限定的空间中,然后使用机械装置将所述材料紧密地包封在所述层之间。可用于制造该包封物的方法包括机械压缩、层张拉、真空密封、或者其它方法。当插入物材料是可压缩的和有弹性的时,其将被牢固地保持在适当的位置而没有起褶、流动、或明显的破裂。在1个大气压的压力下的体积压缩水平在与初始堆密度相比时可以是10%或更多,优选25%或更多,或者更进一步优选40%或更多。
在具体的实施中,所述材料的压缩足以承受、克服或维持在由风、蠕变、机械力或其任意组合引起体积变化的情况下间隙空间中的体积变化。
在另一实例中,通过例如2003年7月29日授权给Rouanet等人的美国专利No.6,598,283B2中公开的技术将气凝胶或另外的合适材料引入到建筑膜结构体中,将该专利的教导全部引入本文作为参考。美国专利No.6,598,283B2描述了例如这样的方法,该方法包括在小于大气压的第一气压下提供包含气凝胶颗粒的密封的第一容器(container)。气凝胶颗粒在第一气压下的不受限体积小于所述气凝胶颗粒在大于所述第一气压的第二气压下的不受限体积。将密封的第一容器置于第二容器例如各外层之间的空间中,并且在所述第二气压下使密封的第一容器形成缺口以使所述第一和第二容器之间的气压平衡并增加气凝胶颗粒的体积,从而形成绝缘制品。
2006年12月7日公布的Dinon等人的美国专利申请公布No.2006/0272727Al中描述的技术也可以适于将插入物材料引入到本文公开的结构体中。美国专利申请公布No.2006/0272727公开了绝缘的管套管(pipe-in-pipe)组件,其包括:(a)至少一个内管,(b)设置于所述至少一个内管周围的外管,从而在所述外管和内管之间产生环形空间,(c)设置于所述环形空间中的多孔的有回弹性的可压缩材料,和(d)先前置于所述环形空间中且先前使所述可压缩材料以小于所述可压缩材料的体积的体积保持在所述环形空间中的容器的残余部分(remnant)。还描述了制造这种绝缘的管套管组件的方法。
在具体的实例中,疏松的粒状材料与粘合剂材料一起用在所述层之间。所述层可以如上所述紧密地包封所述材料,或者可以松散地包封所述材料。在疏松的包封物中,所述层可以类似枕头的形式保持被空气分隔开。在这种情况下,所述插入物材料可完全填充枕头的内部区域或者可以部分填充该区域,通过任选的粘合剂附着到外层中的一个或多个上。
可采用其它合适的方法将粒状材料引入到气承式结构体例如气枕或气垫中。而且,气承式的垫或枕结构体可利用单块的材料和/或复合的材料例如气凝胶毯等形成。
为了使沉降以及空隙的形成减小和最小化,外层之间的空间或间隙体积可以是“过度填充的(overfilled)”或“过度填塞的(overpacked)”。过度填塞的系统可具有至少与振实密度一样高的密度。对于气凝胶颗粒,过度填充是针对高于振实密度的密度而言的。在填充有与相对重的框架相比非常轻的气凝胶颗粒的系统中,其密度可以显著大于振实密度,例如为振实密度的约105%到约115%-120%和更高。
任选地,可以在加入插入物材料以形成建筑膜结构体之前、期间或之后从该插入物材料中除去湿气。
制造或生产过程可进一步包括使第一层、插入物层和第二层(即多个层)中的两个或更多个彼此粘附。还可以采用非粘附技术,导致这些层中的至少两个是非粘附的。将这些层中的两个或更多个连接在一起的具体方法包括将这些层缝合在一起、将这些层层压在一起、将这些层粉末粘结在一起、或者其它合适的技术。这些层可以直接连接,或者它们可以通过居间材料间接地连接在一起。
可用于制造本发明的建筑膜结构体的合适技术包括但不限于层压、粘合、夹在两个张拉层之间、缝合、铆接、在疏松的材料中吹制、湿法加工为复合材料形式等。
本发明的建筑复合材料可以最后加工成板。为了完成复合材料,可以将复合材料结构体的边缘和/或转角密封或夹在一起。利用本发明的复合材料的板的边缘条件示于图2和图3中。图2和图3中还显示了能够与本发明的复合材料组合使用的紧固系统或装置。
例如,图2显示包括用于固定板42的边缘闩(edge bar)40的紧固装置。板42包括例如如上所述的复合材料,该复合材料具有插入物16和任选地密封的外层12和14。该板设置有绳状或珠状的边缘52。边缘闩40夹住各层并且可以被固定到支承或周围部件上。
紧固例如如上所述复合材料的另一方法如图3所示。图3中显示了用于固定包括具有插入物16的复合材料的板62的紧固装置60。在该实例中,所述复合材料包括非结构性的外层64和单一的增强织物外层66,并且所述板使用绳状边缘72和夹子74紧固。
图2和图3中描述的紧固系统可以全部或部分地由铝或另外的合适材料制造。还可以采用除了图2和图3中所描绘的那些之外的紧固方式。
本发明的建筑膜结构体可具有基本上恒定的厚度,该厚度例如为约0.25英寸~约4英寸,优选为约0.375英寸~约3英寸。
在优选的实施中,所述结构体可具有至少为2,优选为约3~38的“R”值,该“R”值是对热流的耐热性的度量。总的结构体或复合材料的合意R值为这样的值,该值大于没有插入物时外层的R值。
优选地,所述建筑膜结构体的热绝缘性能随着负荷或压缩而增强。在具体的实施中,所述结构体具有保持恒定,或者优选随着负荷和/或压缩而减小的热导率(k值)。
在一些实施方式中,所述建筑膜结构体的透光率(%T)例如可见光透光率大于0%,例如至少为约0.25%,优选至少为约0.5%,例如为约0.5%~约2%,更优选至少为2%,例如为约2%~10%,且最优选大于约10%并最高达80%或更高。还优选具有高的光反射率,例如至少60%,优选至少70%且更优选80%或更高的光反射率的复合材料。测量透光率和光谱反射率的合适方法阐述在欧洲标准EN 410或ASTM E424中。
太阳得热系数可以例如为约0.21~0.73。
所述建筑结构体优选提供具有特别的声吸收和扩散性质,并且在40~400Hz范围内在OITC等级(室外室内声音传输等级)方面具有提高的性能。
在优选的实施中,所述建筑膜结构体包括承重绝缘体,即在机械负荷下保持或基本上保持其绝缘性质中的一种或多种例如其热绝缘性质的绝缘体。
在具体实例中,所述插入物在例如风的条件下在所述外层之间传递负荷,其中一个层例如膜抵抗来自一个方向亦即进入到复合材料中的方向的压力,并且另一个层或膜抵抗来自相同方向亦即离开复合材料的方向的压力。这些压力可为约10~40磅/平方英尺(psf)。本文公开的结构体还优选抵抗雪负荷,其中压力通常仅在顶层上发生;这些压力可为20psf至超过100psf。
在一些实施中,外层之一部分地并优选全部由所述插入物支承,或者外层中的两个都部分地并优选全部由所述插入物支承。
在本发明的其它实例中,本文公开的建筑膜结构体具有耐火性能并优选是防火的。而且,所述结构体可以具有耐水性、耐候性和/或耐霉性。
所述结构体或复合材料可构成建筑元件、结构元件或者可用作建筑元件和结构元件两者。与常规的建筑膜一样,本发明的复合材料可用于制造预组装的模块。
在一些实施中,所述建筑膜结构体是气承式垫或气承式枕。
在另外的实施中,本发明的结构体或复合材料用作张拉结构体,该张拉结构体具有由复合材料中的张力和该支承结构体的几何结构所决定的形状。通常,所述结构体包括柔性元件(例如复合材料和缆索)、非柔性元件(例如支柱、支架、梁、环、或拱)和锚具(例如支座和底座)。优选地,在安装时,所述张拉层为底层。
除了三维曲线之外,可以将本发明的复合材料预张拉例如预张拉到基于建筑结构体或复合材料的寿命周期期间的预期负载计算的预张力值。优选地,预张力高到足以在任意可能的条件下在两个方向上都具有最小的张力。如果预张力太低,则复合材料可以变得易于因风而引起振动。如果预张力太高,则复合材料可需要重的且昂贵的支承结构体和/或底座。
可以单独使用或组合使用的形状包括同向弯曲形状,例如球形或穹顶;互反曲形状,例如鞍状;等。因此,本发明的复合材料可安装或预制造为穹顶、锥形、波形、同向弯曲形状、互反曲形状、折叠形状和其它形状。
根据本发明的建筑膜复合材料可用于围护结构体例如屋顶、悬挑、天棚、帐篷和帐篷状结构体、墙、艺术陈列品,可结合到机场、储存设施、飞机库、竞技场、活动中心、运动或集会场地、穹顶、温室、住宅或商业建筑物、制造工厂、博物馆、旅馆、大学、铁路、公交或地铁站、等候区域、电影院、剧院、竞技场、建筑物之间的通道、工业设施中的连接接合点等的设计和施工中的美学或其它结构体。
包括本文公开的复合材料的围护结构体可以用作采用现有建筑膜的围护的替代物,或者除了采用现有建筑膜的围护之外,还可以使用包括本文公开的复合材料的围护结构体。
本文公开的建筑膜结构体可以用作覆面或者可以结合到穹顶和其它建筑物中,例如1988年4月12日授权给Geiger的美国专利No.4,736,553;1992年4月14日授权给Geiger和Campbell的美国专利No.5,103,600;1993年11月16日授权给Wieber等人的美国专利No.5,261,193和1995年7月11日授权给Wieber等人的美国专利No.5,430,979;1996年4月2日授权给Terry的美国专利No.5,502,928;2001年9月4日授权给Simens的美国专利No.6,282,842Bl和许多其它文献中所描述的那些。本文公开的建筑膜结构体可以是现有材料的替代物或者可以与现有材料组合,所述现有材料例如为2006年12月26日授权给Sahlin等人的美国专利No.7,153,792中描述的柔性复合材料。将这些专利的教导全部引入本文作为参考。
例如,图4A和4B中显示了包括墙202和204以及屋顶206的建筑物200。例如本文中所述的复合材料由梁208支承。对于梁208而言,可替代地或者可附加地,可采用其它支承方式,例如加上缆索和/或通过空气压力支承。
将本文公开的复合材料结合到各种建筑设计中的工程方法取决于围护的目的、其功能、形状、所寻求的性质和其它因素。这些方法可以与涉及现有建筑膜的已知方法或者正在被开发的方法相同或者不同。
实例描述于1996年4月2日授权给Terry的美国专利No.5,502,928和1988年4月12日授权给Geiger的美国专利No.4,736,553中,其教导全部引入本文作为参考。其它实例描述于例如下面的可以得自www.geigerenginners.com的出版物中:(i)D.Campbell、D.Chen和P.Gossen P.E.的Design Experience with Nonlinear Tension Based Systems:Tents,Trussesand Tensegrity;(ii)Kazuo Ishii编辑的Membrane Designs and Structures in theWorld;(iii)D.Campbell等人的Tensioned Fabric Membrane Roofs for″Tensegrity″Domes。将这些出版物全部引入本文作为参考。
虽然已经参考本发明的优选实施方式对本发明进行了具体展示和描述,但是本领域技术人员应该理解,可以进行形式和细节上的各种变化而不偏离由所附权利要求所包括的本发明的范围。
Claims (57)
1.包含气凝胶的建筑膜结构体。
2.权利要求1的建筑膜结构体,其中所述气凝胶以气凝胶复合材料、单块存在或者为颗粒形式。
3.权利要求1的建筑膜结构体,其中所述气凝胶存在于毯、毡或片中。
4.权利要求1的建筑膜结构体,其中所述气凝胶存在于纤维-网/气凝胶复合材料中。
5.权利要求1的建筑膜结构体,其中所述结构体具有基本上恒定的厚度。
6.权利要求1的建筑膜结构体,其中所述结构体具有第一层、第二层和在所述第一层与第二层之间的包含所述气凝胶的插入物层。
7.权利要求6的建筑膜结构体,其中所述插入物层具有至少0.375英寸的厚度。
8.权利要求6的建筑膜结构体,包括配置在所述插入物层中的额外的外层或内层。
9.权利要求6的建筑膜结构体,其中所述第一层和第二层中的至少一个是纺织的。
10.权利要求6的建筑膜结构体,其中所述第一层和第二层中的至少一个是无纺的。
11.权利要求6的建筑膜结构体,其中所述第一层和第二层中的至少一个包括玻璃纤维、聚酯、聚四氟乙烯、金属网、纤维棉胎、或其任意组合。
12.权利要求6的建筑膜结构体,其中所述第一层和第二层中的至少一个涂布有聚四氟乙烯、乙烯基树脂、硅树脂、二氧化钛、或其任意组合。
13.权利要求6的建筑膜结构体,其中由所述第一层和第二层所限定的空间基本上被所述气凝胶完全填充。
14.权利要求6的建筑膜结构体,其中由所述第一层和第二层所限定的空间被所述气凝胶部分填充。
15.权利要求6的建筑膜结构体,其中所述第一层和第二层具有相同的厚度。
16.权利要求6的建筑膜结构体,其中所述第一层或第二层具有至少约0.03英寸的厚度。
17.权利要求6的建筑膜结构体,其中所述第一层、所述插入物层和所述第二层中的至少两个是彼此粘附的。
18.权利要求6的建筑膜结构体,其中所述第一层、所述插入物层和所述第二层中的至少两个是彼此不粘附的。
19.权利要求6的建筑膜结构体,其具有被密封或夹住的至少一个边缘或转角。
20.权利要求1的建筑膜结构体,其具有至少为2的热绝缘R值。
21.权利要求1的建筑膜结构体,其具有大于0%的透光率%T。
22.权利要求1的建筑膜结构体,其中所述结构体为张拉结构体。
23.权利要求22的建筑膜结构体,其中所述气凝胶设置于第一层和第二层之间,并且所述各层中仅有一层被张拉。
24.权利要求1的建筑膜结构体,其中所述气凝胶设置于第一层和第二层之间并在所述各层之间传递负荷。
25.权利要求1的建筑膜结构体,其中所述气凝胶附着到层上。
26.权利要求1的建筑膜结构体,其中,在安装时,所述气凝胶受到压缩。
27.权利要求26的建筑膜结构体,其中所述压缩足以承受间隙空间中的体积变化,其中该体积变化是由风、蠕变、机械力、或其任意组合引起的。
28.权利要求1的建筑膜结构体,其中所述气凝胶对压缩具有弹性响应。
29.权利要求1的建筑膜结构体,其中所述气凝胶存在于具有随着负荷或压缩而减小的热导率值的层中。
30.权利要求1的建筑膜结构体,其中所述复合材料具有热绝缘性质、电绝缘性质、隔音性质、或其任意组合。
31.权利要求1的建筑膜结构体,其中所述气凝胶存在于具有不大于0.5g/cm3的密度的层中。
32.权利要求1的建筑膜结构体,其中所述气凝胶存在于具有至少为50%的空隙体积的层中。
33.包括权利要求1的建筑膜结构体的建筑或结构围护。
34.权利要求33的围护,还包括至少一种额外的选自柔性元件、非柔性元件和锚固元件的元件。
35.权利要求33的围护,其中所述围护为屋顶、悬挑、天棚、墙、美学或艺术结构体。
36.权利要求33的围护,其中所述气凝胶在经历体积压缩且随后经历体积膨胀时基本上充满各层之间的空间。
37.包含权利要求33的围护的建筑物。
38.权利要求37的建筑物,其中所述建筑物为机场、储存设施、飞机库、竞技场、活动中心、运动场地、集会场地、穹顶、温室、住宅或商业建筑物、制造工厂、博物馆、旅馆、铁路、公交或地铁站、天棚、通道或大学。
39.包括紧固装置和权利要求1的建筑膜结构体的系统。
40.包含粒状材料的建筑膜结构体。
41.权利要求40的建筑膜结构体,其具有3~38的热绝缘R值。
42.权利要求40的建筑膜结构体,其具有约0.25~约80%的透光率%T。
43.权利要求40的建筑膜结构体,其具有至少80%的反射率。
44.具有基本上保持不变或随着负荷或压缩而减小的热导率的建筑膜结构体。
45.包括基本上承重的绝缘体的建筑膜结构体。
46.包括第一膜层、第二膜层和在所述各层之间的纳米孔材料的建筑膜结构体。
47.权利要求46的建筑膜结构体,其中所述纳米孔材料是单块、颗粒材料或纳米孔复合材料。
48.权利要求46的建筑膜结构体,还包括在所述各层之间的粘合剂材料。
49.制造建筑膜结构体的方法,包括将气凝胶材料固定在第一层和第二层之间。
50.权利要求49的方法,其中所述第一层、含有所述气凝胶材料的插入物层和所述第二层中的至少两个是彼此粘附的。
51.权利要求49的方法,其中所述第一层、含有所述气凝胶材料的插入物层和所述第二层中的至少两个彼此层压在一起。
52.权利要求49的方法,还包括将所述建筑膜结构体的至少一个边缘或至少一个转角密封或夹住。
53.权利要求49的方法,其中所述气凝胶材料为颗粒形式。
54.权利要求49的方法,其中所述气凝胶材料通过机械压缩、层张拉、真空密封、或其任意组合包封在所述各层之间的空间中。
55.权利要求49的方法,其中将所述气凝胶材料提供在置于所述各层之间的至少一个容器中。
56.权利要求55的方法,还包括使所述容器破裂。
57.权利要求49的方法,其中将所述气凝胶材料提供在毯、毡或复合材料中。
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CN105220785B (zh) * | 2015-10-27 | 2018-01-16 | 南京纳世新材料有限责任公司 | 复合保温隔音板 |
CN105220785A (zh) * | 2015-10-27 | 2016-01-06 | 南京纳世新材料有限责任公司 | 复合保温隔音板 |
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CN106626676A (zh) * | 2017-01-23 | 2017-05-10 | 江苏泛亚微透科技股份有限公司 | 绝热隔音气凝胶层复合透气膜的复合材料及其制造方法 |
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CN108000970A (zh) * | 2017-11-20 | 2018-05-08 | 中国科学院紫金山天文台 | 一种新型的保温结构 |
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CN110329175A (zh) * | 2019-05-23 | 2019-10-15 | 连云港冠泰汽车配件有限公司 | 一种乘用车乘员舱nvh被动隔音材料 |
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BRPI0809308A2 (pt) | 2014-09-23 |
CA2682220C (en) | 2017-05-30 |
CN101680222B (zh) | 2016-11-16 |
JP2010525188A (ja) | 2010-07-22 |
EP2142718A2 (en) | 2010-01-13 |
MX2009010228A (es) | 2010-03-22 |
BRPI0809308B1 (pt) | 2018-03-20 |
MX346123B (es) | 2017-03-08 |
AU2008231065B2 (en) | 2014-09-11 |
JP5431972B2 (ja) | 2014-03-05 |
CA2682220A1 (en) | 2008-10-02 |
WO2008118776A2 (en) | 2008-10-02 |
WO2008118776A3 (en) | 2009-02-05 |
US20080229704A1 (en) | 2008-09-25 |
AU2008231065A1 (en) | 2008-10-02 |
KR101556800B1 (ko) | 2015-10-01 |
EP2142718B1 (en) | 2018-04-18 |
KR20090129485A (ko) | 2009-12-16 |
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