Pre-applied protective jacketing construction for pipe and block insulation
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.
1. A composite structure for an outer surface of a pipe, comprising:
first and second arcuate shaped elongated parts that are separate from one another, each of the first and second parts including:
(a) an insulation being made of a porous material, and having an elongated-arcuate-shape having an interior surface sized to complement the outer surface of the pipe, and an exterior surface;
(b) a copolymer-sodium silicate layer, on the exterior surface in bonding contact with the insulation, and within the pores of the insulation, wherein the copolymer-sodium silicate layer includes sodium polyacrylate; and
(c) a flexible outer protective jacketing being formed of a laminate that includes a metal foil and has an adhesive layer on an inner face of the laminate, the outer protective jacketing including a protective release layer disposed on the adhesive layer to permit joining of the outer protective jacketing to the coated insulation member by removal of the protective release layer and joining the adhesive layer to the copolymer-sodium silicate layer of the coated insulation member so as to define an integral composite structure for a one step direct installation on the outer surface of the pipe;
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 such that when the first and second parts mate together, the two first edges mate together and the two second edges mate together, 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 thereon for application to the opposite first or second part to permit the first and second parts to mate together about an outer surface of the pipe.
2. The composite structure of claim 1 , wherein the porous-insulation is comprised of calcium silicate, mineral fiber, rock mineral wool, slag mineral wool, perlite, fiber glass, or a combination thereof.
3. The composite structure of claim 1 , wherein the copolymer-sodium silicate layer is disposed directly upon the exterior surface of the insulation free of any intervening layer.
4. The composite structure of claim 1 wherein the copolymer-sodium silicate layer bonded to the outer insulation surface is comprised of 7.5%-15% sodium silicate and an elastomeric copolymer.
5. The composite structure of claim 1 wherein the laminate further includes a plastic film, and optionally fiberglass cloth.
6. The composite structure of claim 1 , wherein the copolymer sodium silicate layer is formed from a solution has a viscosity ranging from about 57 cP to about 80,000 cP.
7. The composite structure of claim 1 , wherein the copolymer-sodium silicate a viscosity layer is formed form a solution having sufficient to extend within the pores of the insulation.
8. The composite structure of claim 1 , further comprising a release layer removably disposed on the flap so as to expose the pressure sensitive adhesive.
9. A composite structure for an outer surface of a pipe, comprising:
first and second arcuate shaped elongated parts that are separate from one another, each of the first and second parts including:
(a) an insulation being made of a porous material, and having an elongated-arcuate-shape having an interior surface sized to complement the outer surface of the pipe, and an exterior surface;
(b) a copolymer-sodium silicate layer, on the exterior surface in bonding contact with the insulation, and within the pores of the insulation, wherein the copolymer-sodium silicate layer includes sodium polyacrylate; and
(c) a flexible outer protective jacketing being formed of a laminate and has an adhesive layer on an inner face of the laminate, the outer protective jacketing including a protective release layer disposed on the adhesive layer to permit joining of the outer protective jacketing to the coated insulation member by removal of the protective release layer and joining the adhesive layer to the copolymer-sodium silicate layer of the coated insulation member so as to define an integral composite structure for a one step direct installation on the outer surface of the pipe;
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 such that when the first and second parts mate together, the two first edges mate together and the two second edges mate together, 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 thereon for application to the opposite first or second part to permit the first and second parts to mate together about an outer surface of the pipe.
10. A composite structure for an outer surface of a pipe, comprising:
first and second arcuate shaped elongated parts that are separate from one another, each of the first and second parts including:
(a) an insulation being made of a porous material, and having an elongated-arcuate-shape having an interior surface sized to complement the outer surface of the pipe, and an exterior surface;
(b) a copolymer-sodium silicate layer, on the exterior surface in bonding contact with the insulation, and within the pores of the insulation, wherein the copolymer-sodium silicate layer includes sodium polyacrylate; and
(c) a flexible outer protective jacketing being formed of a laminate and has an adhesive layer on an inner face of the laminate, the outer protective jacketing including a protective release layer disposed on the adhesive layer to permit joining of the outer protective jacketing to the coated insulation member by removal of the protective release layer and joining the adhesive layer to the copolymer-sodium silicate layer of the coated insulation member so as to define an integral composite structure for a one step direct installation on the outer surface of the pipe.
11. The structure of claim 10 , wherein the copolymer-sodium silicate layer is formed from a copolymer-sodium silicate solution that is capable of being sprayed on the insulation.