Insulation articles including corrosion inhibitors and methods of producing the same

Abstract

Unique insulation articles including corrosion inhibitors and methods of producing the same are disclosed. One exemplary embodiment is an article of manufacture comprising an insulation mat comprising a cured combination of a plurality of randomly oriented fibers and a binder, the insulation mat extending between a first surface and a second surface, a veil attached to the first surface, the veil structured to inhibit physical movement of the cured combination through the veil, a metal sheet attached to the second surface by a water-containing adhesive contacting the metal sheet and the second surface, and a corrosion inhibitor composition deposited on the cured combination of the insulation mat, the corrosion inhibitor composition being effective to modify toward neutral a pH of the cured combination in contact with water from the water-containing adhesive.

1 . An article of manufacture comprising:
 an insulation mat comprising a cured combination of a plurality of randomly oriented fibers and a binder, the insulation mat extending between a first surface and a second surface;   a veil attached to the first surface, the veil structured to inhibit physical movement of the cured combination through the veil;   a metal sheet attached to the second surface by a water-containing adhesive contacting the metal sheet and the second surface; and   a corrosion inhibitor composition deposited on the cured combination of the insulation mat, the corrosion inhibitor composition being effective to modify toward neutral a pH of the cured combination in contact with water from the water-containing adhesive.   
     
     
         2 . The article of manufacture of  claim 1  wherein the article of manufacture comprises at least one of the following features:
 wherein the cured combination has an acidic pH and the corrosion inhibitor composition has an alkaline pH, 
 wherein the corrosion inhibitor composition comprises a water soluble compound, 
 wherein the water soluble compound comprises at least one of sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate, potassium bicarbonate, ammonium carbonate, ammonium bicarbonate, monoethanolamine, diethanolamine, and triethanolamine, 
 wherein the corrosion inhibitor composition comprises an essentially water insoluble compound, 
 wherein the corrosion inhibitor composition comprises an essentially water insoluble compound and the essentially water insoluble compound comprises at least one of zinc phosphate, calcium phosphate, and a long chain alkyl imidazoline. 
 
     
     
         3 .- 6 . (canceled) 
     
     
         7 . The article of manufacture of  claim 1  wherein the corrosion inhibitor composition is deposited on the first surface of the insulation mat. 
     
     
         8 . The article of manufacture of  claim 1  wherein the article of manufacture comprises at least one of the following features:
 wherein the binder is a non-phenol formaldehyde (PF) composition 
 wherein the binder comprises one of an acrylic binder, a polyester-type binder, a binder which includes at least one reaction product from a Maillard reaction, and a combination thereof, 
 wherein the binder comprises a polyester-type binder based upon one of:
 a monomeric polycarboxylic acid and a monomeric polyol, 
 a polymeric polycarboxylic acid and a monomeric polyol, 
 a monomeric polycarboxylic acid and a polymeric polyol, and 
 a polymeric polycarboxylic acid and a polymeric polyol. 
 
 
     
     
         9 .- 10 . (canceled) 
     
     
         11 . The article of manufacture of  claim 1  wherein the article of manufacture comprises at least one of the following features:
 wherein the binder comprises at least one reaction product from a Maillard reaction, 
 wherein the binder comprises at least one reaction product from a Maillard reaction and wherein the reaction product comprises at least one product of a reducing sugar and an amine reactant, 
 wherein the binder comprises at least one reaction product from a Maillard reaction and wherein the reaction product comprises at least one product of a carbohydrate reactant and a polycarboxylic acid ammonium salt reactant. 
 
     
     
         12 .- 13 . (canceled) 
     
     
         14 . The article of manufacture of  claim 1  wherein the metal sheet is a galvanized metal sheet. 
     
     
         15 . The article of manufacture of  claim 1  wherein the plurality of randomly oriented fibers are one of fiberglass fibers and rock wool fibers. 
     
     
         16 . An article of manufacture comprising:
 an insulation mat comprising a cured combination of a plurality of randomly oriented fibers and a binder, the insulation mat extending between a first surface and a second surface, the cured combination having one of an acidic pH and an alkaline pH when immersed in deionized water;   a veil attached to the first surface, the veil structured to inhibit physical movement of the cured combination through the veil; and   a corrosion inhibitor composition deposited on the cured combination of the insulation mat, the corrosion inhibitor composition having the opposite of the one of the acidic pH and the alkaline pH of the cured composition when immersed in deionized water.   
     
     
         17 . The article of manufacture of  claim 16  wherein the article of manufacture comprises at least one of the following features:
 wherein the article of manufacture further comprises a metal sheet attached to the second surface by a water-containing adhesive contacting the metal sheet and the second surface, 
 wherein the corrosion inhibitor composition is effective to modify toward neutral a pH of the cured combination in contact with water from the water-containing adhesive, 
 wherein the veil is positioned in contact with a surface of a second metal sheet, 
 wherein the veil is positioned in contact with a surface of a second metal sheet and wherein the corrosion inhibitor composition provides passivation of the surface of the second metal sheet, 
 wherein the veil is positioned in contact with a surface of a second metal sheet and wherein the corrosion inhibitor composition provides passivation of the surface of the second metal sheet and wherein the surface of the second metal sheet is galvanized, 
 wherein the binder comprises at least one reaction product from a Maillard reaction, the cured composition has an acidic pH, and the corrosion inhibitor composition has an alkaline pH. 
 
     
     
         18 .- 22 . (canceled) 
     
     
         23 . A method comprising:
 providing an insulation mat comprising a cured 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;   applying a corrosion inhibitor composition to the cured combination of the insulation mat;   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   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 cured combination and the second metal sheet.   
     
     
         24 . The method of  claim 23  wherein the method comprises at least one of the following features:
 wherein the corrosion inhibitor composition is effective to modify toward neutral a pH of the cured combination in contact with water from the water-containing adhesive, 
 wherein the corrosion inhibitor composition is effective to passivate a surface of the second metal sheet, 
 wherein the act of providing an insulation mat includes curing the binder in combination with the plurality of randomly oriented fibers with the veil contacting the first surface effective to provide the cured combination and to attach the veil to the first surface, 
 wherein the act of applying comprises applying the corrosion inhibitor composition to a second surface of the cured combination of the insulation mat, the second surface being opposite from the first surface, 
 wherein the corrosion inhibitor composition is applied to the second surface by spraying one of an aqueous solution including the corrosion inhibitor composition and an aqueous slurry including the corrosion inhibitor composition. 
 
     
     
         25 .- 28 . (canceled) 
     
     
         29 . A method comprising:
 forming an insulation mat comprising a combination of a plurality of randomly oriented fibers and a binder, the insulation mat extending between a first side and a second side;   applying a veil to the first side of the insulation mat;   curing the insulation mat and the veil effective to bind the plurality of randomly oriented fibers and to bind the veil to the first side; and   applying a corrosion inhibitor composition to the second side of the insulation mat;   wherein the cured combination has one of an acidic pH and an alkaline pH when immersed in deionized water, and the corrosion inhibitor composition has the other of the acidic pH and the alkaline pH when immersed in deionized water.   
     
     
         30 . The method of  claim 29  further comprising:
 attaching a first metal sheet to the second side of the insulation mat with a water-containing adhesive contacting the metal sheet and the second surface; and 
 contacting the veil with a surface of a second metal sheet; 
 wherein the corrosion inhibitor composition is effective to inhibit a reaction of water from the water-containing adhesive, the cured combination and the second metal sheet. 
 
     
     
         31 . The method of  claim 30  wherein the method comprises at least one of the following features:
 wherein the surface of the second metal sheet contacting the veil is galvanized, 
 wherein the corrosion inhibitor composition modifies toward neutral a pH of the cured combination in contact with water from the water-containing adhesive, 
 wherein the corrosion inhibitor passivates the surface of the second metal sheet, 
 wherein the binder comprises one of an acrylic binder, a polyester-type binder, a binder which includes at least one reaction product from a Maillard reaction, and a combination thereof. 
 
     
     
         32 .- 34 . (canceled)