Pre-applied protective jacketing construction for pipe and block insulation

• US 8,506,735 B2
• Filed: 06/30/2009
• Issued: 08/13/2013
• Est. Priority Date: 02/02/2007
• Status: Active Grant

• Current Assignee: Industrial Insulation Group LLC (Berkshire Hathaway Incorporated)
• Original Assignee: Industrial Insulation Group LLC (Berkshire Hathaway Incorporated)
• Inventors: Whitaker, Thomas, MacKinnon, Kevin J.
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): Slawski, Brian R
• Application Number:
  US12/494,943
• Publication Number:
  US 20090260751A1
• Time in Patent Office: 1,505 Days
• Field of Search: 156/71, 156/182, 156/196, 156/212, 156/214, 156/242, 156/244.11, 156/278, 156/293, 156/294, 156/314, 156/315
• US Class Current: 156/71
• CPC Class Codes: C04B 14/18 Perlite
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 14/4675 from slags
• CPC Class Codes: C04B 2111/00482 Coating or impregnation materials
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 24/2641 Polyacrylates; Polymethacrylates
• CPC Class Codes: C04B 28/26 Silicates of the alkali metals
• CPC Class Codes: F16L 58/04 Coatings characterised by the materials used F16L58/16 takes precedence
• CPC Class Codes: F16L 59/021 comprising a single piece or sleeve, e.g. split sleeve, two half sleeves
• CPC Class Codes: F16L 59/028 Composition or method of fixing a thermally insulating material
• CPC Class Codes: F16L 59/029 layered
• CPC Class Codes: Y10T 428/1372 Randomly noninterengaged or randomly contacting fibers, filaments, particles, or flakes
• CPC Class Codes: Y10T 428/1376 Foam or porous material containing
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 442/2164 Coating or impregnation specified as water repellent
• CPC Class Codes: Y10T 442/2213 Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant
• CPC Class Codes: Y10T 442/2926 Coated or impregnated inorganic fiber fabric
• CPC Class Codes: Y10T 442/2975 Coated or impregnated ceramic fiber fabric
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric

Abstract

A protective jacketing-insulation composite structure and method is provided for inhibiting the corrosion of a pipeline. The method includes forming a porous-insulation into an elongated-arcuate-shape, applying a sodium silicate solution layer to the insulation and at least partially within the pores thereof, permitting the sodium silicate solution layer to set to a threshold amount, adhering an outer facing to the sodium silicate solution layer after the permitting step is accomplished, installing the insulation and facing to the outer surface of a pipeline, and sealing any exposed edges or seams that may exist between multiple installed products. A structure such as made from this method can have a release layer and contact adhesive.

Claims

1. A method for inhibiting pipe corrosion, the method comprising the steps of:

(a) forming a porous insulation into first and second arcuate shaped parts that are separate from one another, wherein each of the first and second parts has a first edge that runs a length of the part and a second edge that runs a length of the part,

(b) applying a copolymer-sodium silicate solution layer to at least the exterior surface of the insulation of each of the first and second arcuate shaped parts and at least partially within the pores of the insulation, wherein the copolymer-sodium silicate solution layer includes sodium polyacrylate,

(c) permitting the copolymer-sodium silicate solution layer to set to a threshold amount,

(d) adhering an outer protective jacketing directly to the copolymer-sodium silicate solution layer of each of the first and second arcuate shaped parts, after the permitting step is accomplished, wherein the outer protective jacketing includes a pre-applied adhesive layer disposed along a surface thereof and a protective release layer that covers the adhesive to form the outer protective jacketing which is a pre-formed layered component that is separate from the insulation coated with the copolymer-sodium silicate solution layer, the outer protective jacketing of the first part having a first flap portion that extends beyond the first edge of the first part, the outer protective jacketing of the second part having a second flap portion that extends beyond the second edge of the second part, each of the first and second flap portions having a pressure sensitive adhesive formed along an inner surface thereof, wherein the outer protective jacketing comprises a laminate structure including at least a foil material and is flexible so as to allow the first and second flap portions to bend and conform to the arcuate shape of the underlying first and second parts, wherein the step of adhering the outer protective jacketing directly to the copolymer-sodium silicate solution layer comprises removing the protective release layer and placing the adhesive layer of the protective jacketing into contact with the copolymer-sodium silicate solution layer,

(e) installing the product made in steps (a)-(d) onto the exterior surface of a pipe or piece of equipment by placing the first and second arcuate shaped parts about the pipe or piece of equipment such that the two first edges mate together and the two second edges mate together, and

(f) adhering the first flap portion to the second arcuate shaped part about the first edge such that the first flap portion extends circumferentially along an exterior surface of the second arcuate shaped part, and adhering the second flap portion to the first arcuate shaped part about the second edge such that the second flap portion extends circumferentially along an exterior surface of the first arcuate shaped part resulting in the product made in steps (a)-(d) being circumferentially disposed about the pipe or piece of equipment.

2. The method of claim 1, wherein the insulation is comprised of calcium silicate, mineral fiber, rock mineral wool, slag mineral wool, perlite, fiber glass, or a combination thereof.

3. The method of claim 1, wherein the adhering step comprises adhering a continuous outer protective jacketing to the copolymer-sodium silicate solution layer without any intervening layer.

4. The method of claim 1, wherein the applying step comprises brushing the copolymer-sodium silicate solution onto the insulation.

5. The method of claim 1, wherein the applying step comprises spraying the copolymer-sodium silicate solution onto the insulation at a low pressure.

6. The method of claim 1, wherein the laminate comprises a multilayer laminate of foils, plastic film, and optionally fiberglass cloth.

7. A method for inhibiting pipe corrosion, the method comprising the steps of:

(a) forming a porous insulation into first and second arcuate shaped parts that are separate from one another, wherein each of the first and second parts has a first edge that runs a length of the part and a second edge that runs a length of the part;

(b) applying a copolymer-sodium silicate solution layer to at least the exterior surface of the insulation of each of the first and second arcuate shaped parts and at least partially within the pores of the insulation, wherein the copolymer-sodium silicate solution layer includes sodium polyacrylate;

(c) permitting the copolymer-sodium silicate solution layer to set to form a dry layer;

(d) adhering an outer protective jacketing directly to the copolymer-sodium silicate solution layer of each of the first and second arcuate shaped parts, after the copolymer-sodium silicate solution layer has set and formed the dry layer, wherein the outer protective jacketing includes a pre-applied adhesive layer disposed along a surface thereof and a protective release layer that covers the adhesive to form the outer protective jacketing which is a pre-formed layered component that is separate from the insulation coated with the copolymer-sodium silicate solution layer, wherein the step of adhering the outer protective jacketing directly to the copolymer-sodium silicate solution layer comprises removing the protective release layer and placing the adhesive layer of the protective jacketing into contact with the copolymer-sodium silicate solution layer; and

(e) installing the product made in steps (a)-(d) onto the exterior surface of a pipe or piece of equipment.