Patent Application
20190344537
The present application relates generally to insulation materials or articles of manufacture including corrosion inhibitors and methods of producing the same. To form mineral wool insulation materials and articles, such as those comprising fiberglass and/or rock wool, one or more binder compositions may be combined with mineral wool fibers and the binder/fiber combination may be uncured to provide an insulation mat, which may alternatively be referred to as an insulation blanket or simply a blanket. The inventors have discovered that the characteristics of various uncured binder/fiber compositions may contribute to undesired consequences in certain applications, including those where the uncured binder/fiber compositions is ultimately cured for commercial applications. For example, the pH characteristics of uncured binder/fiber compositions may accelerate or contribute to corrosion or hazing of metal material which come into contact with or proximity with either cured or additional, uncured binder/fiber compositions. As one non-limiting example, duct liner articles may be constructed by affixing one side of an insulation mat comprising an uncured binder/fiber combination to a metal sheet and affixing a veil to an opposite side of the mat. During production the “show side” (the side that would be visible in the commercial product) of the metal sheet for one duct liner article may come into contact or proximity with the veil of another duct liner article resulting in corrosion or hazing of the show side that may diminish the commercial value of the affected product. This effect may occur even when sheet metal with a galvanized show side is utilized. A significant need therefore remains for unique insulation materials or articles of manufacture comprising corrosion inhibitors and methods of producing the same.
The present disclosure generally relates to insulation articles comprising corrosion inhibitors and methods of producing the same. In some embodiments, the disclosure relates to an article of manufacture comprising a) an insulation mat comprising an uncured combination of a plurality of randomly oriented fibers comprising fiberglass fibers or rock wool fibers and a non-phenol formaldehyde (non-PF) composition binder, wherein the insulation mat extends between a first surface and a second surface; b) a veil attached to the first surface, wherein the veil is structured to inhibit physical movement of the cured combination through the veil; c) a metal sheet attached to the second surface by a water-containing adhesive contacting the metal sheet and the second surface; and d) a corrosion inhibitor composition deposited on the uncured combination of the insulation mat, wherein the corrosion inhibitor composition modifies toward neutral a pH of the uncured combination in contact with water from the water-containing adhesive.
In some embodiments, the uncured combination has an acidic pH and the corrosion inhibitor composition has an alkaline pH. In further embodiments, the corrosion inhibitor composition comprises a water soluble compound selected from the group consisting of sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate, potassium bicarbonate, ammonium carbonate, ammonium bicarbonate, monoethanolamine, diethanolamine, triethanolamine and combinations thereof. In still further embodiments, the corrosion inhibitor composition comprises a water insoluble compound selected from the group consisting of zinc phosphate, calcium phosphate, a long chain alkyl imidazoline and combinations thereof. In additional embodiments, the corrosion inhibitor composition is deposited on the first surface of the insulation mat. In certain embodiments, the binder is selected from an acrylic binder, a polyester-type binder, a binder comprising at least one reaction product from a Maillard reaction, and combinations thereof.
In some embodiments, the binder comprises a polyester-type binder selected from the group consisting of 1) a monomeric polycarboxylic acid and a monomeric polyol; 2) a polymeric polycarboxylic acid and a monomeric polyol; 3) a monomeric polycarboxylic acid and a polymeric polyol; and 4) a polymeric polycarboxylic acid and a polymeric polyol. In further embodiments, the binder comprises at least one or more of a) at least one reaction product from a Maillard reaction; b) at least one product of a carbohydrate and an amine reactant; and c) at least one product of a reducing sugar reactant and a polycarboxylic acid ammonium salt reactant. In still further embodiments, the metal sheet is galvanized.
In some embodiments, the present disclosure relates to a curable article of manufacture comprising a) an insulation mat comprising an uncured combination of a plurality of randomly oriented fibers and a binder, the insulation mat comprising a corrosion inhibitor composition and extending between a first surface and a second surface, wherein the corrosion inhibitor comprises the opposite of one of the acidic pH and the alkaline pH of the uncured composition when immersed in deionized water; and b) a veil attached to the first surface, the veil structured to inhibit physical movement of the cured combination through the veil. In further embodiments, the curable article comprises a metal sheet attached to the second surface by a water-comprising adhesive contacting the metal sheet and the second surface. In still further embodiments, the corrosion inhibitor composition is effective to modify toward neutral a pH of the uncured combination in contact with water from the water-containing adhesive. In additional embodiments, the veil is positioned in contact with a surface of a second, galvanized metal sheet. In certain embodiments, the corrosion inhibitor composition provides passivation of the surface of the second metal sheet. In additional embodiments, the binder comprises at least one reaction product from a Maillard reaction, the uncured composition has an acidic pH, and the corrosion inhibitor composition has an alkaline pH.
In some embodiments, the disclosure relates to a method comprising a) providing an insulation mat comprising an uncured combination of a plurality of randomly oriented fibers and a binder and a veil attached to a first surface of the cured combination and effective to inhibit physical movement of the cured combination through the veil; b) applying a corrosion inhibitor composition to the uncured combination of the insulation mat; c) curing the uncured combination of a plurality of randomly oriented fibers, a binder, a veil and a corrosion inhibitor; d) attaching a metal sheet to a second surface of the cured combination with a water-containing adhesive contacting the metal sheet and the second surface; and e) contacting the veil with a second metal sheet; wherein the corrosion inhibitor composition is effective to inhibit a reaction of water from the water-containing adhesive, the uncured combination and the second metal sheet.
In further embodiments, the corrosion inhibitor composition is effective to modify toward neutral a pH of the uncured combination in contact with water from the water-containing adhesive. In still further embodiments, the corrosion inhibitor composition is effective to passivate a surface of the second metal sheet. In additional embodiments, the act of applying comprises applying the corrosion inhibitor composition to a second surface of the uncured combination of the insulation mat, the second surface being opposite from the first surface. In certain embodiments, the corrosion inhibitor composition is applied to the second surface by spraying an aqueous solution comprising the corrosion inhibitor composition and an aqueous slurry including the corrosion inhibitor composition. As would be appreciated by those of skill in the relevant art, further embodiments, forms, objects, features, advantages, aspects, and benefits may become apparent from the following description and drawings.
With reference to
In forming insulation mat 112 an uncured binder/fiber combination may be formed using a variety of techniques including, for example, using a spinner to form fibers from molten precursor material, admixing one or more binder compositions with the fibers, and collecting or aggregating the binder/fiber combination. Table 1 below lists a number of non-limiting examples of binder chemistries which may be utilized in forming insulation mat 112 and the pH of each binder in an uncured state (“pH of Uncured Binder”).
Table 2 below provides details as to binder formulations, designated A-H, that may be used in accordance with embodiments of the instant disclosure.
The pH conditions for an uncured binder/fiber compositions for use in certain embodiments of the disclosure for various binders result in uncured binder/fiber compositions having particular characteristics that ultimately and beneficially enhance the commercial value and utility of the resulting, cured binder/fiber compositions. A number of uncured binder/fiber combinations have an acidic pH including, such as the examples listed in Tables 1 and 2 above.
In the embodiment illustrated in
The chemical composition of corrosion inhibitor 113 may be selected to provide at least one of a pH neutralization effect relative to the characteristics of the uncured binder/fiber combination of insulation mat 112, a passivation effect relative to a metal surface which may come into contact or proximity with the duct liner insulation article 110, or a combination of both effects. Accordingly, corrosion inhibitor 113 may comprise a number of different chemical compositions depending on the characteristics of the uncured binder/fiber combination of insulation mat 112. For uncured binder/fiber combinations having an acidic pH, one or more chemical compound(s) characterized by an alkaline pH may be selected as the corrosion inhibitor 113. Table 3 below lists a number of non-limiting alkaline corrosion inhibitors, as well as their water solubility characteristics, for use in the present technology.
In forms where a corrosion inhibitor with an alkaline pH is selected, the corrosion inhibitor 113 may comprise one or more of the alkaline corrosion inhibitors listed in Table 3 above as well as combinations thereof. In further forms where a corrosion inhibitor with an alkaline pH is selected, the corrosion inhibitor 113 may consist essentially of any of the alkaline corrosion inhibitors listed in Table 3 above or may consist essentially of a combination of two or more of the alkaline corrosion inhibitors listed in Table 3 above. It shall be further appreciated that other alkaline corrosion inhibitors may also be utilized in addition to or instead of the non-limiting examples disclosed herein.
For uncured binder/fiber combinations having an alkaline pH, one or more chemical compound providing an acidic pH may be selected as the corrosion inhibitor 113. Table 4 below lists a number of acidic corrosion inhibitors that may be utilized in the disclosed technology.
In embodiments where a corrosion inhibitor with an acidic pH is utilized, the corrosion inhibitor 113 may comprise one or more of the acidic corrosion inhibitors listed in Table 4 above, including combinations thereof. In further embodiments where a corrosion inhibitor with an acidic pH is selected, the corrosion inhibitor 113 may consist essentially of any of the acidic corrosion inhibitors listed in Table 4, including combinations of two or more of the acidic corrosion inhibitors listed in Table 4. In still further embodiments, additional acidic corrosion inhibitors may also be utilized in addition to or instead of the non-limiting examples disclosed herein.
The physical location and extent of the corrosion inhibitor 113 is shown generally in
As further illustrated in
The second side of insulation mat 112 is affixed to metal sheet 115 by adhesive 114, which may be a water containing adhesive such as the VAE laminating adhesive 82000 adhesive offered commercially by EFI Polymers. Other suitable adhesives types include, for example, water-born adhesives, latex emulsions, e.g. polyvinyl acetate (PVA) emulsions, polyacrylate emulsions, ethylene vinyl acetate (EVA) emulsion, and styrene-butadiene emulsions. Metal sheet 115 may be a steel sheet, a stainless steel sheet, or a galvanized steel sheet, wherein the physical location and extent of the adhesive is shown for general reference in
Duct liner insulation articles 110 and 120 of the various compositions and combinations described herein above may be produced according to a process including one or more of the following operations: (a) forming an insulation mat comprising an uncured binder/fiber combination; (b) applying a corrosion inhibitor composition to a first side of the uncured insulation mat; (c) optionally applying a corrosion inhibitor composition to a second side of the uncured insulation mat; (d) affixing a veil to the first side of the insulation mat with a first adhesive; (e) curing the insulation mat to provide an uncured binder/fiber combination; (f) affixing the second side of the insulation mat to a metal sheet with a second adhesive; (f) repeating process operations (a) through (f) to provide a plurality of articles; (g) positioning the resulting articles in contact or proximity with one another; (h) allowing the second adhesive to cure or set for a predetermined period of time; and (i) further forming duct structures using one or more articles as described above.
The configuration illustrated in
Without wishing to be limited to any particular mechanisms or theories, the structure and composition of articles 110 and 120 are believed to mitigate the potential for undesired consequences such as hazing, corrosion, or other chemical reactions affecting the “show side” of a duct liner insulation article by a pH neutralization effect relative to the characteristics of an uncured binder/fiber combination of insulation mat 112 lacking the corrosion inhibitor application described herein, a passivation effect relative to the show side of metal sheet 115, or a combination of both effects. After articles 110 and 120 are initially assembled, adhesives 113 and 123 transition from a wet or unfixed state to a dried or fixed state over a period of time. Moisture from adhesive 113 and 123 may travel through insulation mats 112 and 122, respectively. As this moisture interacts with the uncured binder/fiber combination an acidic or alkaline pH may be imparted to the moisture. Accordingly, the pH neutralization effect of corrosion inhibitors 113 and 123 is believed to modify the pH of the moisture in contact with the uncured binder/fiber combination toward neutral by providing an opposing pH, resulting in a “neutralizing” reaction with respect to pH. The passivation effect of corrosion inhibitors 113 and 123 is believed to involve movement of the corrosion inhibitor through the insulation mats 112 and 122 and veils 111 and 121 to contact an adjacent metal surface where the corrosion inhibitor passivates the metal surface by chemically interacting with binding sites that might otherwise be reactive to the pH of the uncured binder/fiber composition.
In compositions and processes that include the use of galvanized metal sheets a particular mechanism of action may occur wherein an initially shiny metal surface of the zinc metal reacts with the moisture to form hydrated zinc oxides. The surface areas in contact with moisture can become dulled and also exhibit a white haze. The appearance of the surface is non-uniform and is objectionable for aesthetic and/or commercial applications, especially in those cases where the affected surface is an exposed surface or “show side” in construction applications. Mitigating these issues is not simple or straightforward and represents a well-established problem in the insulation and building industries. One complication is that the presence of acidic or alkaline compounds, such as the disclosed corrosion inhibitors, may themselves provide undesired corrosion or reactions producing similar results. Another complication is that the corrosion inhibitors themselves may produce objectionable results, for example, providing a non-uniform or blemished surface when applied directly to a metal surface or directly onto the surface of an adjacent article that comes in contact of the galvanized steel. Additionally, the identification of concentrations and/or application densities for the corrosion inhibitor system is not straightforward and can significantly vary between application processes and corrosion inhibitor systems. In many instances the applied corrosion inhibitors form an undesirable film or crust on the galvanized steel surface. In these embodiments a surprising result occurred by application of the corrosion inhibitor to the uncured composition as illustrated in
With reference to
It shall be appreciated that the embodiment of
Although the present disclosure is primarily directed to uncured compositions comprising the uncured binder/fiber combinations contemplated herein, duct liner insulation articles that are well known to those of skill in the relevant arts may be produced by processing the uncured binder/fiber combinations comprising one or more corrosion inhibitors according to previously reported techniques and processes, which may comprise one of more of the steps pf (a) applying a veil to the first side of an insulation mat; (b) curing the insulation mat in contact with the veil to provide a cured binder/fiber combination affixed to the veil; (c) affixing the second side of the insulation mat to a metal sheet with an adhesive; (d) repeating process operations (a) through (c) to provide a plurality of articles; (e) positioning the resulting articles in contact with or proximal to one another; (f) allowing the adhesive to set for a predetermined period of time; and (g) further forming duct structures using one or more articles.
Alternate techniques and orders of operations for applying the veil may be utilized including, for example, those described above in connection with
Referring now to
As will be appreciated by the skilled artisan, embodiments of
Duct liner insulation articles 310 and 320 of the various compositions and combinations described herein above may be produced according to a process including the following operations: (a) forming an insulation mat comprising an uncured binder/fiber combination, (b) applying a veil to the first side of the insulation mat, (b) applying a corrosion inhibitor composition at interior locations in the insulation mat using techniques such as penetrating injection needles, penetrating injection nozzles, or penetrating sprays, (c) curing the insulation mat in contact with the veil to provide a cured binder/fiber combination affixed to the veil, (e) affixing the second side of the insulation mat to a metal sheet with an adhesive, (f) repeating process operations (a) through (e) to provide a plurality of articles, (g) positioning the resulting articles in contact with or proximity with one another, (h) allowing the adhesive to set for a predetermined period of time, and (i) further forming duct structures using one or more articles.
Alternate techniques and orders of operation for applying the veil may be utilized including, for example, those described above in connection with
With reference to
It shall be appreciated that certain embodiments of
While the technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected. Accordingly, no limitation of the scope of the disclosure is thereby created, and that the technology includes and protects such alterations, modifications, and further applications of the exemplary embodiments as would occur to one skilled in the art. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.
This application claims priority to U.S. Application Ser. No. 62/669,936, filed May 10, 2018, the entire disclosure of which is expressly incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 62669936 | May 2018 | US |
