WO2020127494A1

WO2020127494A1 - Insulation material

Info

Publication number: WO2020127494A1
Application number: PCT/EP2019/085966
Authority: WO
Inventors: Chun Jun RONG
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-12-19
Filing date: 2019-12-18
Publication date: 2020-06-25
Anticipated expiration: 2021-06-19
Also published as: GB2579867A; GB201820694D0; EP3898222A1

Abstract

A protective layer for protecting a body is disclosed. The protective layer comprises at least one cloth layer and at least one aerogel paste layer arranged over the at least one cloth layer. A body comprising one or more surfaces covered with the protective layer is also disclosed. This concept may be referred to by the term "Climate Plating".

Description

Insulation material

The present invention relates to the field of protective or insulation materials. In particular, it relates to a protective layer for protecting a body, a body comprising one or more surfaces covered with a protective layer, and methods of producing the same.

Throughout human history, people have protected themselves from the environment. A plethora of insulation materials have been employed, starting with naturally-occurring materials from animals and plants. Most of them are soft with lots of gaps or air pockets, as air itself is an excellent insulator. Some examples of such soft, air-trapping insulation materials include cotton, straw, grass and wood fibres, e.g. as used in ancient times, and glass fibres, mineral fibres, etc. as used in the modern era.

Today, insulation materials are used, for example, to protect against high- temperatures, thermal maintenance and freezing cold, but also for sound insulation, repelling water, fire protection and corrosion protection, to mention a few examples. Materials selected for these insulation purposes can be supplied as blocks, panels or fibres, but in some cases also using small grains or nanoparticles. Most insulation materials contain air to lighten their weight whilst yielding effective insulation. However, many such materials have limitations of use, being effective only in specific areas or in certain conditions. If conditions change dramatically, most insulation materials will cease to work. For instance, they may catch fire and burn if the temperature increases dramatically, or take in water and lose their insulation properties if they get wet.

Aerogels can provide an insulation material which retains a high insulation value even following environmental changes (e.g. increases in temperature) which could cause a fire risk. An aerogel is a lightweight, manmade product derived from a gel in which the liquid component has been replaced with a gas.

Aerogels possess the attractive property of being a solid insulator, which does not become compressed or deformed when subjected to a typical external force. This is in contrast to how most fibrous materials behave under strains or pressure. This endows aerogels with unique insulation properties that offer high value, solid insulation.

Although aerogel production has developed very fast in the last decades, it is still very expensive due to the difficult and demanding technology needed for such chemical production. Despite considerable effort in this area, aerogel presently costs around ten (or more) times more than alternative, conventional insulation materials. However, aerogel characteristics are unmatched by conventional insulation. Hence, aerogel insulation is increasingly the material of choice for many applications where insulation is required.

As well as cost, known aerogel materials themselves also have some limitations.

Aerogel_.materials can only be made from small particles because aerogels contain more than 95% air and, as a consequence, aerogels are readily fragmented into small pieces and dust. So far, aerogel products (e.g. Pyrogel® and Cryogel®) are widely used in many oil, gas and other insulation-dependent industries.

Nevertheless, these materials do not provide a solution to the problem of dust, which has serious health and welfare implications for workers during installation, for a healthy environment and for humans during its lifetime of maintenance, and finally during recycling. Furthermore, there are vexing problems arising when attempting to integrate such insulation materials into everyday products. So far, many launched products have deficiencies because they are soft and dusty, and unsuited for touch by humans. Consequently, use of cladding to protect aerogel products from human touch is necessary. However, this introduces complications of engineering, cost and compatibility issues with regards to desired insulation goals.

There is therefore a need to provide an improved aerogel insulation material.

According to a first aspect of the invention, there is provided a protective layer for protecting a body, the protective layer comprising at least one cloth layer and at least one aerogel paste layer arranged over the at least one cloth layer.

As discussed above, aerogels can provide excellent insulation properties, e.g. compared to the same volume, thickness or weight of other conventional insulation materials. Aerogels are lightweight and can be fire resistant. However, simply using an aerogel on its own produces a very dusty and crumbly material, which can fall apart or disintegrate over time, produce dust and therefore be messy and potentially hazardous to health. It also means that it is difficult to recycle as it will crumble easily.

The inventor of the present application has discovered that by providing the aerogel in the form of an aerogel paste, this can reduce or eliminate the dusty properties of the aerogel, and provide a material that is not dusty (or less dusty than known aerogel insulation materials) and not (or less) messy or hazardous to health.

Furthermore, using an aerogel paste means that it can be easily applied to a support layer or material, such as the at least one cloth layer.

The at least one cloth layer could be any layer formed of a woven material, e.g. to which the insulation paste may be applied.

The provision of a cloth layer beneath the insulation paste can provide structure and strength, and produce an insulation material which can be easily applied to an object to be insulated.

Providing the aerogel in the form of an aerogel paste means that, before the paste dries, the protective layer can be flexible and thus more easily applied to a body to be protected, e.g. in particular one with non-planar surfaces.

Thus, the present invention provides a protective layer comprising at least one cloth layer with at least one aerogel paste layer arranged over the at least one cloth layer. Such a protective layer can provide good insulating properties due to the use of aerogel, is non-dusty as the aerogel is provided in the form of a paste, and can be easily applied to a body to be protected.

An aerogel paste is a paste comprising an aerogel material. It may have any of the optional or preferred features described below. The aerogel material in the aerogel paste is preferably provided as particles of aerogel material. The aerogel particles may be 1 - 10 nm in diameter, for example.

The protective layer may comprise two or more cloth layers with an aerogel paste layer arranged between each pair of adjacent cloth layers. The provision of, e.g., a second cloth layer, on top of the aerogel paste, can for example protect the aerogel paste, e.g. from external causes of damage. It could also provide a suitable external surface for a desired use.

The protective layer may comprise more than one layer of aerogel paste, e.g. with each layer of aerogel paste provided on top of a cloth layer.

In some embodiments, the insulation material comprises three or more cloth layers with insulation paste layers arranged between adjacent cloth layers (and possibly also on top of an upper cloth layer). By providing an insulation material with three or more cloth layers with insulation paste layers arranged between adjacent cloth layers, this can provide an insulation material with greater insulation and protective properties than one with fewer cloth and/or aerogel paste layers. However, of course, it is thicker. Thus, in some cases, a thinner insulation material with only one or two cloth layers may be preferred.

At least one of the at least one cloth layers (and in some cases preferably all of the at least one cloth layers) is/are preferably formed of a temperature resistant fibre cloth. For example, at least one of the at least one cloth layers may be formed of a silicon dioxide cloth. Thus, as well as providing an insulating layer, the protective layer can also provide protection against high temperatures or fire and can help to ensure that the protective layer will not degrade, melt or be otherwise affected by high temperatures. It can also protect a body to which it is applied from high temperatures and/or fire.

If two or more cloth layers are used in the insulation material, they need not necessarily be made of the same material, although in some embodiments they may be made of the same material. For example, an uppermost cloth layer may be formed of a different material (e.g. a stronger, waterproof and/or more protective material) than the one or more other (lower) cloth layers, which could (each) be formed of the same material such as a silicon dioxide cloth, for example.

In some embodiments, the protective layer may further comprise an outer protective layer, wherein the outer protective layer is preferably provided or arranged (in use) as an outer surface of the protective layer. The outer protective layer may be formed of a plastic or rubber material such as silicone rubber. The outer protective layer may be made of a non-cloth (e.g. non-woven) material.

The outer protective layer is preferably water and/or fire resistant. Thus, it can further protect a body from environmental conditions.

In some embodiments, the protective layer may further comprise an inner protective layer, preferably made of a plastic or rubber material such as silicone rubber.

In some embodiments, both an outer and an inner protective layer, preferably made of a plastic or rubber material such as silicone rubber, are provided. This can help to seal and protect the other layers from the environment.

It can also result in a relatively soft protective layer, which can, for example, be easily bent and manipulated to fit contours on a body to be protected with the protective layer. It can also provide a smooth protective layer which feels smooth to touch.

References to“inner” and“outer” in this application refer to inner and outer surfaces of the protective layer in use. For example, an inner protective layer may form a surface of the protective layer which, in use, is adjacent or attached to a body to be protected by the protective layer. An outer protective layer may form a surface of the protective layer which, in use, is arranged furthest from a body to be protected by the protective layer, thereby forming an outer (exposed) surface of the body protected (covered) with the protective layer.

The aerogel paste preferably comprises glue. This can help to hold or bind aerogel particles in the paste, and thereby provide a non-dusty protective layer.

The use of glue also means that the paste can adhere to objects to which it is applied, and a different or further form of attachment might not necessarily be required.

The glue is preferably a temperature-resistant glue. This can help to ensure that the proactive layer is resistant to high temperatures and/or fire, and will not degrade, melt or be otherwise affected by high temperatures.

In an example, the glue comprises Al₂0₃ and/or Si0₂ (the aerogel).

Alternatively, the aerogel paste may comprise Al₂0₃ and/or Si0₂, i.e. Al₂0₃ and/or Si0₂ may be added to the paste separately (i.e. Al₂0₃ and/or Si0₂ may not be provided in the glue). Including Al₂0₃ in the glue and/or aerogel paste can increase the temperature tolerance of the aerogel paste, e.g. to above 600°C.

In some embodiments (e.g. where a temperature tolerance of greater than 600°C is not required), Al₂0₃ is not included in the glue and/or aerogel paste. This can leave more room for aerogel (e.g. Si0₂) in the paste.

The aerogel paste preferably comprises silicon dioxide aerogel, and preferably particles of silicon dioxide aerogel. Silicon dioxide aerogel is a good insulator, relatively cheap compared to other aerogels, and fire-resistant or resistant to high temperatures. However, the aerogel need not necessarily be silicon dioxide and other types of aerogel could alternatively be used such as aluminium aerogel.

The aerogel paste preferably comprises one or more of: water, a coupling agent and an aqueous dispersion agent, and preferably all of these. The water is preferably pure water. These ingredients, when mixed with aerogel material (e.g. particles of aerogel material), can produce an aerogel paste of a convenient consistency for application to a cloth layer, for example.

The aerogel paste is preferably formed by mixing (or blending) its constituents together. Using a blender can help to ensure complete and thorough mixing of the components. For example, aerogel particles may first be mixed with (at least) water, optionally with a coupling agent and/or an aqueous dispersion agent, to form a paste. This helps to produce a paste of a convenient consistency for application or use, and can aid (possibly subsequent) mixing of the aerogel with the glue. Glue and/or A!₂0₃ and/or Si0₂ may then be mixed with this to form the aerogel paste.

The protective layer may be made according to the method described below, with any of its optional or preferred features.

According to a second aspect of the invention, there is provided a body comprising one or more surfaces covered with a protective layer. The protective layer is the protective layer described above according to the first aspect, with any of its optional or preferred features.

Covering one or more surfaces of a body with a protective layer as described above, can provide a body which is protected from environmental conditions such as changes in temperature and/or moisture.

Preferably, all of the body’s surfaces (or outer/inner surfaces) are covered with the protective layer such that the body is completely covered or protected from environmental conditions.

The protective layer may be attached to the body with glue (e.g. the glue described above such as a temperature resistant glue) or an aerogel paste (e.g. as described above and used in the protective layer itself), for example. Using, for example, the aerogel paste, to attach the protective layer to the body can provide additional insulation/protection of the body.

In some cases, two or more pieces of the protective layer may be attached or applied to the body. For example, the two or more pieces of the protective layer may be attached to the body in layers on top of each other (e.g. to provide a greater level of insulation or environmental protection), and/or the two or more pieces of the protective layer may be attached to the body adjacent to each other (e.g. to provide greater or complete coverage of a body, perhaps more easily than applying a single piece of insulating material over the body).

One piece of the protective layer may be used to cover each (e.g. each distinct) surface of the body. Alternatively or additionally, e.g. in the case of relatively large bodies, two or more pieces of the protective layer may be used to cover a surface (e.g. a distinct surface) of the body, e.g. when arranged adjacent to each other. A further piece (or further pieces) of the protective layer may be arranged on top of these pieces. Any gaps between the two or more pieces of the protective layer are preferably filled with aerogel paste. This can help to ensure a complete

insulating/protective covering of a body.

A further protective layer or cladding may be applied over the protective layer. The further protective layer or cladding may be made of aluminium, stainless steel, plastic, or glass fibre, for example.

The body may be or comprise a wall, a panel, a cylinder, a cable, a pipe, a vehicle, a building, a cabin, a compartment, a layer, a platform, a block, a brick or a plate, or an assembly of layers, platforms, blocks, bricks or plates, for example.

A layer, platform block, brick or plate may be partially or completely formed of one or more plastic materials. Other, non-plastic, materials could also be used to form the layer, platform, block, brick or plate, for example.

The body (e.g. wall) may be made of steel, lumber, plywood, and/or other suitable materials, for example.

In some embodiments, the body may be a layer, platform, block, brick or plate, such as a plastic layer, platform, block, brick or plate, where the plastic layer, platform, block, brick or plate is preferably formed of, or comprises, recycled (i.e. old or previously used) plastic. The layer, platform, block, brick or plate may also or alternatively be formed of other (non-plastic) waste material.

For example, the layer, platform, block, brick or plate may be (e.g. at least partially) formed of (e.g. burnable) plastic, which could be provided in the form of pellets and formed (e.g. crushed) into plastic layers, blocks or bricks, or other such configurations. Thus, burnable plastics (e.g. which may not be otherwise or more conventionally recyclable), may be used to create a useful construction material, particularly when covered with a protective layer, according to the present invention. This can help to remove plastics (e.g. such burnable plastics) from being a recycling problem, and can instead provide a (semi-) permanent disposition into a durable, light-weight and non-burnable construction material with a new value.

The body could be a wall or assembly of such layers, platforms, blocks, bricks or plates.

Thus, the layers, platforms, blocks, bricks or plates could be individually covered with the protective layer. Alternatively (or additionally), the layers, platforms, blocks, bricks or plates could be assembled into a wall or assembly and then that wall or assembly could be covered with the protective layer. The assembly of such new layers, platforms, bricks, plates or walls, preferably including the covering of them with the protective layer, may be performed at a site or factory/installation at which the waste is sorted and/or plastic is recycled.

Plastics, many of which are non-degradable, currently pose a big problem in the world. One way to handle plastics is to recycle them. For that, many countries have invested in sorting facilities for plastic waste. However, after the plastics are sorted, people often have few uses for them. This is because most countries lack industries which can re-use plastics. For the past 40 years, China accepted more that 75% of the world's plastics. However, after China banned imports of plastic waste, 75% of the world’s plastic waste remains in place, i.e. it has not been dealt with or recycled. Countries must now handle their own waste, including plastics. The problem is that most countries lack suitable infrastructures for recycling plastics. Moreover, countries that do recycle plastics have few or no industrial uses for such plastics.

Currently, plastics are typically handled by landfills or incineration, both of which have negative societal and environmental consequences. Landfills are cheapest but finding available sites can be difficult. Burning waste reduces volumes for landfills and allows the generation of electricity. However, incineration pollutes and poisons the atmosphere. Both methods are now restricted by new European Union rules.

Using layers, platforms, bricks, blocks or plates made (at least partially) of waste plastic, and covering them with a protective layer, as described above, provides an advantageous solution to the problem of handling waste plastics. Such layers, platforms, bricks, blocks or plates covered with a protective layer may be manufactured in a single factory, which may be performed in an environmentally friendly manner. In addition, such layers, platforms, bricks, blocks or plates covered with a protective layer can provide a semi-permanent product, which may be suitable for use as a construction material, for example.

Household waste is typically separated into five fractions:

1. Recyclable

2. Mix-3D

3. Mix-2D

4. Bigger than 6 mm

5. Smaller than 6 mm. These fractions are explained in more detail below.

A typical sorting facility will tend to produce similar quantities by volume of each fraction. For example, waste may be sorted into the fractions 1-5 above in the following percentages (by volume): 15%, 6%, 9%, 34%, 36%, respectively.

Fraction 1 contains recyclable waste. Around 10-12% of this fraction is typically almost 99% (or higher) pure plastics in different types, such as HOPE, PP, LDPE, PET and PS. The rest of this fraction comprises paper, metal and glass. Around 2-5% of this can be put to use directly.

Fraction 2 contains so-called“Mix-3D” waste. This is solid, rigid, three- dimensional waste, including mixed hard plastics (around 15%), textiles (around 15%), and the rest (about 70%).

Fraction 3 contains so-called“Mix-2D” waste. This is soft, flat, two- dimensional waste, including mixed film plastics (around 30%), textiles (around 15%), and the rest (about 55%).

Fraction 4 contains“Bigger than 6 mm” waste. This is mixed waste with dimensions larger than 6 mm, which typically constitutes 34% of the total waste.

Fraction 5 contains“Smaller than 6 mm” waste. This is mixed waste with dimensions less than 6 mm, which typically constitutes 36% of the total waste.

A single“green” factory or installation, for example, (e.g. producing layer, platforms bricks, blocks or plates covered with a protective layer as described above) may be able to make use of all fractions of the waste and leave no waste to the environment, thereby providing a zero waste facility.

Layers, platforms, bricks, blocks or plates (e.g. suitable for covering with a protective layer as described above) may be formed (completely or at least partially) from waste from different fractions described above.

Different recyclable plastics, e.g. in almost pure (e.g. at least 99% pure) separated status, may be used to make plastic products such as layers, platforms, bricks, blocks or plates. For example, layers, platforms, bricks, blocks or plates may be formed from almost pure fractions of different types of plastics from fraction 1.

One such layer or platform may be a soft or bendable platform, which may be provided in the form of rolls.

Another such layer platform may be a rigid platform, which may be provided in the form of rigid plates. These platforms may be produced from different types of plastics.

Preferably, such platforms are formed by flattening the plastic material(s) from which they are formed.

Some of the waste fractions described above contain a mixture of different wastes (non-pure fractions). This waste, for example from fractions 2 or 3, may be used to produce bricks, blocks or plates. These may be of standard or

constant/consistent sizes, for example, e.g. such that they can be easily combined and/or built with.

Some of the waste fractions described above contain waste sorted by size (e.g. fractions 4 and 5). This waste may also be used to form bricks, blocks or plates.

Thus, waste from fraction 1 may be used to form rigid and soft plastic platforms and/or waste from any or all or fractions 2-5 may be used to form preferably standard size bricks, blocks and plates. These platforms, bricks, blocks or plates may be used as building blocks and construction materials, e.g. to build a building.

The layers, platforms, bricks, blocks and plates formed from waste as described above are preferably covered (e.g. at least partially) with a protective layer, as described above. This can help to improve their appearance, strength and odour. Applying a protective layer as described above can also make the layers, platforms, bricks, blocks and plates fire-resistant (un-burnable) and/or waterproof, protecting them from water damage, for example. The protective layer can also protect the layers, platforms, bricks, blocks and plates (or buildings constructed from these bodies) from atmospheric wear.

As described above, platforms may be provided which are made of various (e.g. waste) materials, particularly plastics, which have preferably been flattened and may be applied with a protective layer as described above.

The platforms may be formed by recycling sorted waste plastics. These plastic fractions are preferably almost (e.g. at least 99%) pure, These platforms can provide new uses for plastics which would otherwise be found to have little or no use.

Typically, most of the sorted plastic waste is LORE, so platforms such are those described above may be mainly made of recycled LORE, e.g. that are at least 99% pure. These may be used to form soft rolls or rigid plates, e.g. as described above. Some of the other sorted out plastics, such as PP, HOPE, PET, and PS, may also or alternatively be used to make platforms. Some plastics like HOPE may only be used to make rigid platforms. However, they tend to be rarer, constituting very little volume of the total waste plastic materials, so it is expected that (at least currently) only a small amount of platforms would be formed or rarer plastics.

Soft platforms are preferably made of recycled plastics which are melted together, e.g. at a temperature of 150 to 250 °C, spread out and then stretched out, e.g. to form plastic rolls. These platforms may be thinner than the rigid platforms.

Rigid platforms are preferably made of recycled plastics which are melted together, e.g. at a temperature of 150 to 250 °C, spread out and then fixed into standard size plastic plates, for example.

Bricks, blocks and plates may be made from any or all of sorted out waste fractions 2-5, for example. These fractions are normally not recyclable. However, with the present invention, they may be put to new uses, e.g. as solid building materials.

Fraction 2 typically comprises mostly larger size, three-dimensional, solid, rigid waste, including hard plastics, textiles, and other rigid solid waste, for example. These mixed rigid solids may be mechanically broken down by a machine into smaller pieces, then preferably combined with a glue, pressed together, heated up, e.g. to 150 to 300 °C, and then stabilised into preferably standard size bricks, blocks and plates.

Fraction 3 typically comprises mostly larger size, two-dimensional, soft, flat waste, including mixed film plastics, textiles, and soft film wastes, for example. These mixed soft solids may be mechanically broken down by a machine into smaller pieces, then combined with a glue, pressed together, heated up, e.g. to 150 to 300 °C, and then stabilised into preferably standard size bricks, blocks and plates.

Fraction 4 typically comprises mixed solid wastes of sizes larger than 6 mm, but limited in sizes. This waste may be optionally broken down by a mechanical machine into smaller pieces, then combined with a glue, pressed together, heated up, e.g. to 150 to 300 °C, and stabilised into preferably standard size bricks, blocks and plates.

Fraction 5 typically comprises mixed solid wastes of sizes less than 6 mm, so they not need to be broken down by a mechanical machine into smaller pieces. These may be combined with a glue directly, pressed together, heated up, e.g. to 150 to 300 °C, and stabilised into preferably standard size bricks, blocks and plates.

Layers, platforms, bricks, blocks and plates as described above may be used to form a physical construction such as a building, for example.

Such a construction may comprise a frame such as a metal (e.g. steel), concreted or wooden frame or carrying/support structure. This frame or

carrying/support structure may then be filled in and/or covered with bricks, blocks and plates as described above. Platforms as described above, or another kind of supporting plate, may be used to fix and support the bricks, blocks and plates.

A protective layer, preferably as described above, is preferably applied to the layers, platforms, bricks, blocks and/or plates from which the construction is formed. Other kinds of finishing protection may additionally or alternatively be applied.

Such a construction or building may be used as factory building, for example, to house the production of such platforms, bricks, blocks and/or plates.

Preferably, all waste fractions 1-5 above (e.g. if they cannot or would not otherwise or better be recycled) are preferably used to form layers, platforms, bricks, blocks and/or plates as described above. This can thereby offer an environmentally friendly alternative to landfills and to incineration, resulting in a cleaner Earth and cleaner air.

The above are just examples of the kinds of bodies to which a protective layer (according to the invention) may be applied, and other bodies or objects may of course also or alternatively be covered.

According to a third aspect of the invention, there is provided a method of protecting one or more surfaces of a body with a protective layer, the method comprising attaching or applying one more pieces of the protective layer to the body. The protective layer is the protective layer described above according to the first aspect, with any of its optional or preferred features.

The method preferably comprises attaching the protective layer to the body with glue or an aerogel paste (e.g. as described above).

The method may comprise attaching or applying two or more pieces of the protective layer to the body. The two or more pieces of the protective layer may be attached to the body in layers on top of each other, and/or the two or more pieces of the protective layer may be attached to the body adjacent to each other. The method may comprise filing any gaps between the two or more pieces of the protective layer with aerogel paste. This can help to provide a complete, seamless or gapless covering or protection over the body.

Preferably, the method further comprises drying the protective layer (e.g. the aerogel paste in the protective layer) or allowing the protective layer to dry. The drying may be performed, for example, by ambient heating or by heating the protective layer with a heater (e.g. a blower heater). The drying is preferably performed after the protective layer has been attached to the body. Once the protective layer is dry, it is then (preferably) in a hardened state. Following drying, the protective layer may have reduced in size slightly, e.g. producing a snug fit to the body being protected.

The method may comprise applying a further protective layer or cladding over the protective layer. The further protective layer or cladding may be made of aluminium, stainless steel, plastic, or glass fibre, for example.

The body may be or comprise a wall, a panel, a cylinder, a cable, a pipe, a vehicle, a building, a cabin, a compartment, a layer, a platform, a block, a brick or a plate, or an assembly of layers, platforms, blocks, bricks or plates (e.g. as described above). The body (e.g. wall) may be made of steel, lumber, plywood, and/or other suitable materials, for example. In some embodiments, the body may be a plastic block or brick, where the plastic block or brick is preferably at least partially formed of, or comprises, recycled (i.e. old or previously used, waste) plastic, e.g. as described above. The body could be a wall or assembly of such blocks or bricks, e.g. as described above.

According to a fourth aspect of the invention, there is provided a method of making a protective layer, the method comprising providing at least one cloth layer and applying at least one aerogel paste layer over (or onto) the at least one cloth layer.

The protective layer is preferably the protective layer described above in relation to the first aspect, with any of its optional or preferred features.

Once made, the protective layer may be rolled into rolls, for example, preferably before the aerogel paste has dried and hardened.

The rolls are preferably wrapped (e.g. in plastic) or placed in a e.g. plastic container. This can help to prevent the aerogel paste from drying and hardening before the protective layer has been attached or applied to a body. A fifth aspect of the invention relates to the use of a protective layer for protecting and/or insulating and/or fireproofing and/or waterproofing a body. The protective layer is that described above in relation to the first aspect, with any of its optional or preferred features.

The present invention, as described above in relation to its various aspects, provides an aerogel-based protective layer which can be used for insulating or protecting various bodies, e.g. from environmental conditions. This protective layer can be only millimetres in thickness, for example.

The invention may provide a simple, single layered (e.g. single layer of insulation paste) protective layer, e.g. by sandwiching insulation paste between two cloth layers (e.g. fire resistant cloths) using, for example, a special high temperature resistant glue.

Additionally or alternatively, the invention may provide a“complex” protective layer, e.g. by stacking additional layers of insulation paste and cloth layers on top of the simple, single layered insulation material, e.g. by using a temperature resistant glue, and repeating the process for example up to 6-8 times, before finally covering the top insulation paste layer with a fire resistant cloth layer or other outer protective layer, for example.

The present invention can provide bodies with superior insulation properties, e.g. compared to those with conventional forms of insulation.

Products or bodies insulated with the protective layer of the present invention can have excellent insulation values. For example, the protective layer may tolerate and withstand high temperature fires with flames over 1200°C, for example, while at the same time also being able to tolerate and withstand low temperatures down towards absolute zero degree.

The protective layer of the present invention can be thinner than

conventional insulation materials providing the same level of insulation. For example, the protective layer of the present invention can usually be at most only one fifth of the thickness of conventional fibre insulation materials such as glass fibre or mineral fibre materials for the same level of insulation.

Additionally, the protective layer of the present invention can be a solid, relatively rigid (non-deforming) insulation material (e.g. once dried and hardened).

The special properties of the protective layer of the present invention can protect objects from fire in buildings, walls, cars, boats, trains, helicopters, airplanes, pipes, pipelines, storage compartments, etc., while simultaneously being highly space-efficient (compact or thin).

The protective layer of the present invention may be produced with conventional manufacturing techniques, e.g. at a factory. However, the protective layer may alternatively be produced“on site” (e.g. at or close to the body to be insulated), e.g. to customised shapes and sizes that fit the body to be insulated, thereby avoiding the need to trim or cut insulation material made a factory, e.g. in a standard or predefined range of set sizes.

The present invention may provide a seamless covering of bodies with the protective layer, e.g. by applying the protective layer while it is still in a soft and pliable state (e.g. while the insulation paste in the protective layer is still moist/wet and soft).

Once installed on a body, and snuggly fitted, the protective layer may be hardened (or allowed to harden) by removing water from (drying) the insulation paste in the protective layer, e.g. by ambient heating. This drying treatment can result in the protective layer reaching a solid state only after attachment to a surface or body.

Initial attachment of the protective layer to a body may be by a temperature resistant glue, and/or by mechanical means (e.g. a screw or nail).

Once dried and hardened, the protective layer can no longer be

(significantly) deformed or compressed, for example.

Any gaps between pieces of the protective layer applied to a body can be filled with insulation paste, for example, thereby providing a seamless covering of the body, whether a vehicle, a house, a cockpit, a battery, etc.

An important advantage of the protective layer is that there is no (or little) fragmentation or dust from the aerogel in the protective layer during installation. Adherence of the protective layer to bodies or objects preferably takes place while the insulation paste in the protective layer is still in the form of a semi-solid paste (i.e. it has not yet dried, or not yet completely dried). Hence, possible biohazards from aerogel particles in the protective layer can be avoided during installation. Similarly, dust problems during maintenance, remodelling or recycling of the protective layer can be minimal because the aerogel is provided in a paste, e.g. mixed with glue. Providing the aerogel within the protective layer affixed to bodies can achieve significant risk reduction to human health and to insulation workers compared to previous use of aerogels in or as insulation materials. Installing the protective layer according to the present invention can also lead to marked space savings compared to the use of conventional insulation materials, since the thickness of the protective layer according to the present invention is around one fifth of that of conventional insulation yet it offers superior insulation properties. While this space-saving aspect is an advantage in itself, it also provides for a lighter insulation. The lighter weight and reduced dimensions of the protective layer according to the present invention can provide significant advantages for vehicles and aeroplanes, as well as during eventual replacement and recycling after repairs or damage.

Furthermore, the ease of shaping of the protective layer according to the present invention, e.g. (exactly) to the features of a body to be insulated, can streamline and facilitate the installation process and reduce the requirement for special training of skilled workers. Similarly, the ability to customise the protective layer on site (e.g. to a required shape and size) can generate significantly less waste of expensive insulation materials compared to the use of prefabricated insulation materials.

One embodiment of the present invention, which may be particularly advantageous for smaller items, e.g. for safeguarding, comprises making an exposed surface of a protective layer (or body with a protective layer) (e.g. as described above) more attractive in its visual appearance and/or more pleasant to touch. As such, the method may comprise rubberizing an exposed surface, preferably to endow this surface with leather-like properties and feel. This may be achieved by applying an aerogel rubber to an (otherwise) exposed surface. As such an outer surface of a protective layer or body, as described above, may comprise or be formed or an aerogel rubber.

Thus, the method of applying or attaching a protective layer to a body, e.g. as described above, may be performed on a non-exposed surface of a body (i.e. a surface which, at the end of the method, is not an exposed surface). This may then be following by applying an aerogel rubber to the outer surface of the protective layer, e.g. such that an outer surface of the covered body comprises or is formed from an aerogel rubber.

This embodiment may be particularly useful for bodies whose outer appearance and/or of feel is of particular importance to a user, such as a suitcase, a furniture piece, a chamber wall, etc. This embodiment may thus provide enhanced comfort of a covered item, whilst still retaining the protective properties of other embodiments.

Aerogel rubber, as mentioned above, may be formed of a mixture comprising silicon rubber (e.g. acting as glue), an aerogel paste, and preferably also a fire retardant. For example, an aerogel rubber mixture may comprise:

around 40 g of silicon rubber (acting as a glue), around 80 g of aerogel paste, and around 35 g of fire retardant. Of course, to make larger or smaller quantities, the respective weights may be scaled up or down appropriately.

Aerogel paste may be provided in two varieties.

Aerogel paste may comprises water (83-84% weight %), with the remaining weight being formed of aerogel powders. This is equivalent to aerogel at 70-80% volume, with the remaining volume being provided by water.

A dispersant may be added to the paste to allow mixing of the ingredients at intermediate (not high) speeds to produce an aerogel paste.

An aerogel rubber mixture may be is applied to one (e.g. a front or rougher) side of a temperature resistant fibre cloth (in a protective layer) and this is then preferably heated, e.g. to 300 - 400 °C, e.g. in an oven, preferably until dried.

A silicon rubber mixture is preferably placed on another (e.g. back or smoother) side of the temperature resistant fibre cloth. This is then preferably heated, e.g. to 300 - 400 °C, e.g. in an oven, preferably until dried.

A finished product with an outer aerogel rubber layer, e.g. as described above may be 1.8 m wide and 0.6 mm thick. This may stop blue-flame fires, with a Lambda insulation value of 0.081 W/mK. In this process, some smoke (material classification A2 S1 dO) may develop until the aerogel rubber layer is all gone.

Two examples of finished products with an outer aerogel rubber layer, e.g. as described above, are presented below:

For a 1.2 mm thick external sheet with an outer aerogel rubber layer:

Temperature resistant fibre cloth: 950 g / m²

Back side: silicon rubber (acting as glue) 65 g / m² Front side: aerogel rubber (acting as glue) 155 g/ m²

For a 0.6 mm thick external sheet with an outer aerogel rubber layer:

Temperature resistant fibre cloth 950 g/ m²

Back side: silicon rubber 32 g / m²

Front side: aerogel rubber 78 g / m² The insulation performance over the lifetime of the protective layer according to the present invention can be greatly enhanced, compared to known insulation materials, since there is no deformation of the protective layer over time, e.g. due to the effects of gravity or repairs on the state of the protective layer, which otherwise would tend to reduce the insulation performance of conventional materials.

The protective layer according to the present invention is formed of a non- dusty aerogel material, which can be suitable for most types of insulation application, including high temperature insulation, thermal insulation, cold insulation, sound insulation, water repelling, fire protection, corrosion protection and may be made open for vapour diffusion.

The protective layer according to the present invention may have a range of uses, e.g. from extreme low to extreme high temperatures.

The protective layer according to the present invention may be made available as both mouldable sheets and/or rigid plates, and it can reduce the total material requirement to around one fifth of that of conventional materials for comparable insulation.

Embodiments of the protective layer according to the present invention meet EU requirements for transport, offshore and construction uses, with a design which may satisfy future HSE standards.

The protective layer according to the present invention can allow easy fitting with perfect adhesion to any part of an installation, which in combination with hydrophobic and non-dusty properties can provide an excellent defence to corrosion (or corrosion under insulation).

The protective layer according to the present invention can provide very low thermal conductivity at extremely low (-270°C) to extremely high (over 1200°C) temperatures. This makes the protective layer according to the present invention an outstanding thermal insulation material compared to existing products.

Embodiments of the protective layer according to the present invention have been jet-fire tested and certified to meet the strict requirements in the transport and construction industries for passive fire protection.

The protective layer according to the present invention can be fully resistant to exposure to outside conditions without using any cladding, and all properties may be provided within just thin layer of material, so the product is ideal for installations in congested areas, for example. Further, a single layer thickness of the protective layer according to the present invention can have the same insulation effects as traditional insulation five times its thickness, whether formed of plastics, glass fibres, mineral or rock wool, etc. even though their K-values could be similar.

The protective layer according to the present invention may be removed for inspection. This may facilitate the following making of repairs (e.g. if

needed/desirable) such as patching repairs.

Finally, by eliminating dust production during installation, using the protective layer according to the present invention can safeguard not just the entire work area and keep it clean, but also the health of the workers installing aerogel- based insulation. The protective layer according to the present invention is comfortable to work with, making the work more efficient and less expensive. This fact is of course equally relevant during remodelling of insulated areas by reducing dust. The corollary is that during eventual removal and recycling of an insulated structure, the problems of disposal become minimized compared to the alternatives.

Being resistant to high temperatures or temperature-resistant means that the material will not degrade or be changed by high temperatures.

Preferred embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which:

Fig. 1 A is a photograph of a protective layer according to an embodiment, with an egg and a pen for comparison;

Fig. 1 B is a photograph of a protective layer according to an alternative embodiment;

Fig. 1 C is a photograph of an underside of a protective layer according to an embodiment;

Fig. 2A is a cross-sectional schematic illustration of a protective layer according to an embodiment;

Fig. 2B is a cross-sectional schematic illustration of a protective layer according to an alternative embodiment;

Fig. 2C is a schematic diagram illustrating the manufacturing process for a further alternative embodiment of a protective layer;

Fig. 2D is a cross-sectional schematic illustration of the protective layer being manufactured in Fig. 2C;

Fig. 3 is a schematic perspective illustration of the passage of liquid water and water vapour in relation to a protective layer according to an embodiment;

Fig. 4 is a schematic diagram illustrating the production of an aerogel paste; Fig. 5 is a further schematic diagram illustrating the production of the aerogel paste;

Fig. 6A is a cross-sectional schematic diagram illustrating how a protective layer according to an embodiment is installed;

Fig. 6B is a cross-sectional schematic diagram illustrating how the installation of the protective layer according to an embodiment is finished;

Fig. 7 A is a cross-sectional schematic diagram illustrating how a protective layer according to an alternative embodiment is installed;

Fig. 7B is a cross-sectional schematic diagram illustrating how the installation of the protective layer according to an alternative embodiment is finished and repaired;

Fig. 8A is a cross-sectional schematic diagram illustrating the installation of a non-planar protective layer according to an embodiment;

Fig. 8B is a perspective partly cut-away schematic diagram illustrating the installation of the non-planar protective layer according to an embodiment;

Figs. 9A and 9B are schematic front views of walls with a protective layer according to an embodiment (Fig. 9A) and with conventional insulation (Fig. 9B).

Figs. 10A and 10B are schematic cross-sectional views of walls upgraded with a protective layer according to an embodiment (Fig. 10A) and with

conventional insulation (Fig. 10B).

Fig. 11 is a schematic perspective view of a safe box insulated with a protective layer according to an embodiment;

Fig. 12 is a schematic perspective view of a safe room insulated with a protective layer according to an embodiment;

Fig. 13 is a schematic perspective view of a safe house insulated with a protective layer according to an embodiment;

Fig. 14 is a schematic cross-sectional view of a high-rise building insulated with a protective layer according to an embodiment;

Fig. 15A is a schematic cross-sectional view of a car with a cabin insulated with a protective layer according to an embodiment;

Fig. 15A is a schematic side view of a car cabin insulated with a protective layer according to an embodiment;

Fig. 16A is a schematic cross-sectional view of an aeroplane with a cabin insulated with a protective layer according to an embodiment; Fig. 16B is a schematic cross-sectional view of a helicopter with a cabin insulated with a protective layer according to an embodiment;

Fig. 16C is a schematic cross-sectional view of a train with carriages insulated with a protective layer according to an embodiment; and

Fig. 16D is a schematic cross-sectional view of a ship with a cabin and cargo or fuel compartment each insulated with a protective layer according to an embodiment.

The present invention relates to protective layers 100, 100 A, 200, as illustrated in Figs. 1A, 1 B, 2A, 2B, 2C and 2D.

A first embodiment of the protective layer 100 is shown in Figs. 1A and 2A. The protective layer 100 comprises a surface layer 101 and a base layer 102. The surface and base layers 101 , 102 are each made of a temperature resistant fibre cloth, such as a silicate (silicon dioxide) fibre layer. When the protective layer 100 is applied to a body to be protected, the protective layer 100 is oriented such that the surface layer 101 forms an outermost surface, and the base layer 102 forms an innermost surface of the protective layer 100.

Between the surface and base layers 101 , 102, is provided an insulation layer 103. The insulation layer 103 is made from an aerogel paste 10 which is described in more detail below. As described below, when the aerogel paste 10 dries, it hardens, making the protective layer 100 relatively hard and rigid once dried.

The surface and base layers 101 , 102 are each around 1.6 mm in thickness.

A second embodiment of the protective layer 200 is shown in Fig. 2B. This is similar to the embodiment of Fig. 2A except that it has more layers. Like the protective layer 100, the protective layer 200 has a surface layer 201 and a base layer 203. However, the insulation material 200 also has two intermediate layers 202 provided between the surface layer 201 and base layer 203. The surface layer 201 , base layer 203 and intermediate layers 202 are each made of a temperature resistant fibre cloth, such as a silicate (silicon dioxide) fibre layer. Three insulation layers 204 are interspersed between the surface, base and intermediate layers 201 , 203, 202. The insulation layers 204 are made from the aerogel paste 10 which is described in more detail below. The surface, base and intermediate layers 201 , 203, 202 are each around 1.6 mm in thickness. Like the protective layer 100, protective layer 200 is also relatively hard and rigid once the aerogel paste 10 has dried. ln an alternative embodiment, more intermediate layers 202 are provided. For example, up to five or six intermediate layers 202 can be provided, with insulation layers 204 provided between them. Alternatively, a single intermediate layer 202 can be provided. The total thickness of a protective layer with one or more intermediate layers 202 can be around 4 to 12 mm.

In some embodiments, the surface layer 101 , 201 is made of a different cloth material to that of the base layer 102, 203 (and intermediate layers 202, if present). In one embodiment, the surface layer 101 , 201 is made of a surface protection cloth such as a fireproof and/or windproof fabric, and the base layer 102, 203 and, if present, intermediate layers 202 are made of temperature resistant fibre cloths made of silicate fibres.

In some embodiments, the surface layer 101 , 201 , base layer 102, 203 and/or, if present, intermediate layers 202 are made of a silicon dioxide cloth where the silicon contents are 80% by weight. Such a cloth can be provided with a thickness of 0.25 mm, 1.5 mm or 2 mm, for example.

An alternative embodiment of a protective layer 100A is shown in Figs. 1B, 1 C, 2 C and 2D. The protective layer 100A has a base layer 102, an insulation layer 103 and a surface layer 104. The base layer 102 and insulation layer 103 are as described above and below. The protective layer 100A has a surface layer 104, which is made of silicone rubber. A silicone rubber surface layer 104 provides a smooth outer surface to the protective layer which feels good (e.g. like leather) to a user’s sense of touch. It can protect the rest of the protective layer 100A from environmental factors.

However, in an alternative embodiment (not shown in the figures), the base layer 102 also has a silicone rubber surface or backing on its lower (inner, in use) side.

In such embodiments, i.e. when a silicon rubber surface is applied to the top and/or bottom surfaces of the protective layer, this can prevent the aerogel paste 10 in the insulation layer 103 from drying and hardening, and thereby results in a soft and flexible protective layer.

As can be seen from the photograph in Fig. 1 A, in which a sample of the protective layer 100 is shown next to an egg 1 and a pen 2 for comparison, the protective layer 100 is very thin. In this case it has a thickness of around 3.2 mm. The egg 1 is 6.3 cm in length and the pen 2 is 14 cm in length. Fig. 1A shows the uppermost side (i.e. the fibre cloth surface layer 101 ) of the protective layer 100. Fig. 1 B shows a sample of protective layer 100A, with a silicone rubber surface layer 104, next to a ruler. In Fig. 1 B, the smooth silicone rubber surface layer 104 is visible.

Fig. 1C shows the underside (i.e. the fibre cloth base layer 102) of the sample of protective layer 100A shown in Fig. 1 B, next to a ruler. However, it should be noted that this is also how the fibre cloth base layer 102 of the protective layer 100 would appear, being made of the same material.

The photographs shown in Figs. 1A-1C are all shown at approximately the same magnification.

As described above, the insulation layers 103, 204 are made of an aerogel paste 10. This aerogel paste 10 is formed of an immobilised aerogel. The immobilised aerogel does not allow liquid water to pass through it. However, as the aerogel is formed mainly of air, it does allow water vapour to slowly pass through it. This is illustrated in Fig. 3, in which the straight, upwardly pointing arrows 3 indicate how water vapour can pass through the protective layer 100, and the curved arrows 4 indicate how liquid water is repelled from the upper surface of the protective layer 100 and is unable to pass through it.

The aerogel paste 10 will now be described in more detail with reference to Figs. 4 and 5.

In order to make the aerogel paste 10, dry silicon dioxide aerogel 5 is provided in the form of particles. The particles are 1 - 10 nm in diameter. To the aerogel particles are added pure water, a coupling agent 6 and aqueous dispersion agent 7 (around 20% v/v). This is then all mixed rigorously in a blender (as indicated by the dashed circular arrows in Fig. 5) to produce a wet aerogel paste 8. In the wet aerogel paste 8, the aerogel particles contain fixed water with only minimal extra water between the aerogel particles.

A temperature resistant glue 9 is then added to the wet aerogel paste 8 (in roughly equal parts) and this is then mixed to create the (moist) aerogel paste 10. The temperature resistant glue 9 is a watery mixture comprising Al₂0₃.

In a preferred embodiment, the dry aerogel 5 is a silicon dioxide aerogel with 97% air.

In some embodiments, the temperature resistant glue 9 is 40% Al₂0₃ and 30% Si0₂ (by weight).

In some embodiments, the temperature resistant glue 9 is 30% Al₂0₃ and 20% Si0₂ (by weight). ln some embodiments, the temperature resistant glue 9 is that described in Chinese patent application CN 101823866.

In some embodiments, the temperature resistant glue 9 has the following composition by weight %:

MgO: 1 - 2%

H₃PO₄: 37.25 - 40.35%

AI(OH)₃: 16-18.5%

Cr₂0₃: .5-3.5%

Al₂0₃: 15.5-19.4%

Formalin: 1.5-2%

Na₂S0₄: 0.15-0.25%

Si0₂: 20%

Formalin is an anti-degrading agent.

In some embodiments, the silicon dioxide aerogel is added to the glue, and then mixed with the other components.

In other embodiments, the silicon dioxide aerogel is mixed with other components first, and then that mixture is mixed with a glue which does not contain silicon dioxide.

In order to form the protective layers 100, 100A, 200, using the aerogel paste 10, the following steps are performed.

First, the aerogel paste 10 is spread by a machine onto a base layer 102, 203. If an intermediate layer 202 is being used, this is then placed on top of the first layer of aerogel paste 10 and more aerogel paste 10 is applied on top of the intermediate layer 202. More intermediate layers 202 and layers of aerogel paste 10 are then added, if required (e.g. depending on the level of insulation required). The surface layer 101 , 104, 201 is then applied on top of the uppermost layer of aerogel paste 10 to form the protective layer 100, 100A, 200.

Initially, the protective layer 100, 200 formed in this way is soft and flexible. However, as the aerogel paste 10 dries, it also hardens, and the protective layer 100, 200 itself becomes hard. Depending on the conditions, the thickness of the protective layer 100, 200, and/or or any outer layer provided on the protective layer 100, 200, drying can take between 2 hours and 2 days, for example. However, as the protective layer 100A has a silicone rubber surface layer 104, it does not harden like protective layers 100 and 200, but remains soft and flexible. The above process can be used to make lengths of the protective layer 100, 100A, 200. For example, 50 m lengths of the protective layer 100, 100A, 200 which are 1 m wide can be made (weighing around 80 kg, depending on the thickness). These lengths of the protective layer 100, 100A, 200 can be rolled into rolls. The rolls can be sealed (e.g. in a plastic covering or bag) to prevent the aerogel paste 10 in the protective layer 100, 200 from drying and hardening. Thus, the sealed rolls of the protective layer 100, 200 are stable (i.e. they remain soft and flexible) until they are installed and allowed to dry and harden. From such rolls, the required amount of protective layer 100, 100A, 200 can be cut to cover a particular object (e.g. a pipe, wall or other item).

A particular example of how the protective layer 100A can be manufactured is illustrated in Fig. 2C. Here, a moving production device 105 such as a conveyor belt carries a base layer 102 along in the direction of arrow 106. On top of the base layer 102 an aerogel paste 10 is applied to form the insulation layer 103. The paste 10 is flattened and allowed to dry (or dried). Then, silicone rubber 12 with colour and fire-retardant properties is applied on top of the insulation layer 103 to form the surface layer 104. The silicone rubber 12 is also flattened and allowed to dry (or dried).

The installation of the protective layer 100, 100A, 200 on various objects will be described in more detail below.

As well as being thermally insulating, the protective layer 100, 200 formed in this way is also fire resistant, lightweight and corrosion resistant. It can also provide sound-proofing as sounds cannot pass though it (or only minimally). Furthermore, the high level of insulation it provides means that a thinner amount of it is needed to provide the same level of insulation when compared with conventional insulation materials. Finally, by forming the protective layer 100 200 from aerogel provided in the form of the aerogel paste 10 described above, this provides a non-dusty protective layer 100, 200, compared with known insulation materials using aerogel.

Figs. 6A and 6B illustrate how the protective layer 100 is installed on an object to be insulated 300.

First, as shown in Fig. 6A, pieces of protective layer 100 (e.g. cut to the required size) are attached to the object to be insulated 300 with temperature resistant glue 9, which is applied between the base layer 102 of the protective layer 100 and the object to be insulated 300. Alternatively, the pieces of protective layer 100 are attached to the object to be insulated 300 with aerogel paste 10 (which contains temperature resistant glue 9), again between the base layer 102 of the protective layer 100 and the object to be insulated 300.

Small gaps 400 may remain between pieces of protective layer 100, e.g. when more than one piece of protective layer 100 is used to cover the object 300. These gaps 400 are filled with aerogel paste 10 to complete the insulation of the object to be insulated 300. Filling such gaps 400 in this way can help to ensure that the object 300 is protected from corrosion from its environment.

Subsequently, in some embodiments, the whole upper surface of the protective layer 100 is covered with a protective material or cloth such as a silicone rubber layer.

Once the protective layer 100 has been installed on an object to be insulated 300, it can be left to dry and harden in the ambient temperature or it can be heated (e.g. with an air dryer) to assist in its drying and hardening. As the protective layer 100 dries and hardens, it also shrinks slightly thereby ensuring a snug fit with the object to be insulated 300.

Figs. 7A and 7B illustrate how the protective layer 200 is installed on an object to be insulated 300.

First, as shown in Fig, 7A pieces of protective layer 200 (e.g. cut to the required size) are attached to the object to be insulated 300 with temperature resistant glue 9, which is applied between the base layer 203 of the protective layer 200 and the object to be insulated 300. Alternatively, the pieces of protective layer 200 are attached to the object to be insulated 300 with aerogel paste 10 (which contains temperature resistant glue 9), again between the base layer 203 of the protective layer 200 and the object to be insulated 300.

Due to the increased thickness of the protective layer 200 compared to the protective layer 100, the protective layer 200 is also attached by means of mechanical attachment (screws) 1 1.

As above, small gaps 500 may remain between the pieces of protective layer 200, e.g. when more than one piece of protective layer 200 is used to cover the object 300. There may also be small gaps or holes around the mechanical attachments 11 (or in the place where the mechanical attachments 1 1 were installed, after they have been removed). These gaps 500 are filled with aerogel paste 10 to complete the insulation of the object 300.

Any holes or damage that may occur to the protective layer 100, 200 during its use or lifetime can be easily repaired with insulation paste 10. ln some embodiments (not shown), the protective layer 100, 200 is installed on opposing sides (e.g. inner and outer) of an object to be insulated, such as a wall or panel.

Figs. 8A and 8B illustrate how the protective layer 100 can be installed on a cylindrical object 600 (e.g. a pipe or column) to be insulated. In this example, a layer of aerogel paste 10 is applied to the outer surface of the cylindrical object 600. Over this, a first layer of the protective layer 100 is applied. Around this, a metal band 800 is applied to keep the first layer of protective layer 100 in place. Next, another layer of aerogel paste 10 is applied over the first layer of protective layer 100. Over this, a second layer of protective layer 100 is applied and a second metal band 800 is applied around the second layer of protective layer 100 to keep the second layer of protective layer 100 in place. Finally, a protective cloth or cladding 700 is applied around the second layer of protective layer 100 and second band 800. A further metal band (not shown) can be applied around the cladding 700 to keep the cladding 700 in place.

The cladding 700 can protect the protective layer 100 from possible causes of damage, for example. The cladding 700 can be aluminium, stainless steel, plastic, or glass fibre cladding, for example.

In some embodiments, and depending on the length of the object 600, a number of metal bands 800 may be applied, e.g. along its length, to keep the various layers in place.

So that the protective layer 100 can be applied around the cylindrical object 600, it is applied to it in its unhardened state, i.e. when it is still flexible. Depending on the portability (or lack thereof) of the object to be insulated 600, and in order to provide the protective layer 100 in its unhardened state, the protective layer 100 can be made on site, for example with portable machines.

In some embodiments, the protective layer 200 is used instead of protective layer 100. Different numbers of layers of protective layer 100, 200 can also be used depending, for example, on the level of insulation required and/or the space available.

Uses of the protective layers 100, 200 are multiple. The protective layers 100, 200, when attached to an object so as to cover its surface completely constitutes a type of“artificial skin” for such objects. Such objects may be big or small, or part of a larger object. Uses of the protective layers 100, 200 include but are not limited to building construction and building renovation. Similar uses are found in offshore

installations, in space installations and in industrial on-shore installations.

Furthermore, compartments (e.g. cabins) insulated with the protective layer 100, 200 are useful in aeroplanes and helicopters, as marine vessel insulation and corrosion protection, and for insulation of cars, buses, trains, refrigerated trailers or mobile homes. Smaller compartments insulated with the protective layer 100, 200 can be useful for battery insulation/protection especially in electronic cars and vehicles; electronic equipment insulation including handheld devices, phones, PCs and computers, and in protective clothing for fire fighters, etc.

In general, any item that is in need of fire protection, thermal protection, cold protection, corrosion protection, water protection, and/or other special needs, could be usefully protected by the protective layer 100, 200. Special additional uses are evident by production of more complex protective layers (e.g. 200) to gain properties relevant for special applications.

The protective layer 100, 200 can be particularly useful in building construction as it is lightweight, has high insulation properties, is fireproof, and controls water and vapour transmission as described above. In large buildings, considerations of weight, fire protection, insulation and ventilation are important, but often, with conventional solutions, not all of these can be achieved without detriment to one of the others. Use of protective layer 100, 200 in such

constructions can offer desirable solutions in many respects without such conventional costly compromises.

The protective layer 100, 200 may readily be attached to building surfaces by mechanical means and/or by glue, as described above. By using the protective layer 100, 200, tall buildings can be relieved of weight constrictions, thinner walls can allow for more usable space both in terms of floor space and in terms of building heights, fireproofing can eliminate serious safety concern in high-rise buildings, and ventilation controls can improve climate and energy efficiencies in buildings.

In building walls, the protective layer 100 may be attached both inside and outside of the building construction walls.

The inner surface protective layer 100 can be attached to the wall, for example in an office or apartment, to allow conventional walling to be presented as the interior. If the conventional wall represents a fire hazard, for example, the protective layer 100 may be used to form the interior wall surface, to be decorated by wallpaper or paint, for example.

On the outer surface of buildings, the protective layer 100 should be covered by conventional facade cladding. The protective layer 100 will regulate climate (sun, wind and rain) transfer where the protective layer 100 is attached to a calcium carbonate (concrete) plate, for example, or any conventional plate.

In summary, use of the protective layer 100, 200 in buildings can provide a sturdy and fully insulated wall or barrier with the advantage of a 3-10 fold reduction in thickness compared to currently available alternative walls or barrier layers. Furthermore, unlike present know aerogel insulation materials, which are very dusty or crumbly, with the use of the protective layer 100, 200, aerogel or material loss (dust) from the insulation material 100 is almost completely avoided.

Figs. 9A and 9B are schematic front views of insulated walls 900, 950 (e.g. of a building) with a protective layer 100 according to an embodiment (Fig. 9A) and with conventional insulation 150 (Fig. 9B), respectively.

Figs. 10A and 10B are schematic cross-sectional views of insulated walls 900, 950 upgraded with protective layers 100 according to an embodiment (Fig. 10A) and with conventional insulation 150 (Fig. 10B), respectively.

As can be seen in Figs. 9A and 10A, with the protective layer 100, the whole framework 905 of the wall 900 can be covered by the protective layer 100.

However, as shown in Figs. 9B and 10B, with only conventional insulation 150, only the spaces between the framework 955 are filled with insulation material 150. The reason that the whole framework 905 of the wall 900 can be covered with protective layer 100 is that the protective layer 100 is significantly thinner than conventional insulation 150, e.g. for the same level of insulation. As conventional insulation 150 is so thick, it is only provided in the spaces between the framework 955, or it would take up too much space or increase the thickness of the wall 950 too much. As the whole wall 900, including its framework 905, can be seamlessly covered with protective layer 100, without taking up too much space, this provides improved insulation compared to when conventional insulation material 150 is used only in the spaces between the framework 955.

After the protective layer 100 has been applied to the wall 900, external wall elements can be equipped with vents 915 and/or cladding 910, e.g. for decorative or protective purposes. The internal surface of the protective layer 100 can be wallpapered, painted or left as it is. Figs. 11 to 16 illustrate some further possible uses of the protective layer

100.

The protective layer 100 can be used to produce objects that are fully (or nearly fully) insulated and/or protected by the protective layer 100.

Fig. 11 shows a safe box 1000 insulated with (or formed from) protective layer 100. The safe box 1000 could be used for the storage of batteries or other items requiring protected storage, for example. Many items, such as batteries, documents, etc., are in need of complete compartmentalization to either protect them from outside hazards such as fires (e.g. documents), or alternatively to protect the surroundings from hazards arising in the enclosed compartments (e.g. from heavy duty electrical batteries in cars, phones, etc.). The protective layer 100, or pieces of the protective layer 100, can be moulded or joined to form a complete shell, thereby providing a much improved safety compartment compared with what may be achieved with conventional insulation methods and materials.

Fig. 12 is a schematic perspective view of a safe room 1100 insulated with protective layer 100. This is an example of an enclosed space which is insulated with the protective layer 100. The protective layer 100, or pieces of protective layer 100, can be moulded or joined to form a complete shell around or forming a safe room, thereby providing a much improved safe room compared with what may be achieved with conventional insulation methods and materials.

Fig. 13 is a schematic perspective view of a safe house 1200 insulated with protective layer 100. Many geographical locations such as Australia and California are prone to devastating fires. Complete insulation of a dwelling 1200 with protective layer 100 will vastly increase its protection from devastating brushfires, for example.

Fig. 14 is a schematic cross-sectional view of a high-rise building 1300 insulated with protective layer 100. In such cases, various intensities (thicknesses) of protective layer 100 can be used. With the increasing construction of high-rise buildings in modern times, has come the increasing incidence of catastrophic fires in such high-rise buildings. By insulating floors, rooms, zones or areas of the building 1300 with various intensities (thicknesses) of protective layer 100, protection against the spread of isolated fires may be attained to a superior degree, or, in principle, in totality by containing fires to (smaller) segments of the building 1300. The insulation with protective layer 100 of compartments, rooms or zones within the existing structure of the building 1300 can be achieved without loss of valuable living space, as is the case with conventional insulation methods, due to the thinness of the protective layer 100 required.

The protective layer 100 can be used in vehicles, as illustrated in Figs. 15 and 16, to create insulated (and fire-proof) cabins. Since the protective layer 100 is formed initially in a soft form, it can be moulded into most shapes and can therefore be moulded to fit varying shaped cabins. This can be particularly useful in the insulation of vehicles, such as cars, buses, helicopters, airplanes, trains, ships, satellites, etc.

Figs. 15A and 15B show a car 1400 with a cabin 1500 insulated with protective layer 100.

Fig. 16A shows an aeroplane 1600 with a cabin 1650 insulated with protective layer 100.

Fig. 16B shows a helicopter 1700 with a cabin 1750 insulated with protective layer 100.

Fig. 16C shows a train or truck 1800 with carriages or trailers 1850 insulated with protective layer 100.

Fig. 16D shows a ship 1900 with a cabin 1950 and cargo or fuel

compartment 1910, each insulated with protective layer 100.

Although certain figures have been described above in relation to protective layer 100, it will be appreciated that protective layer 200 could be used instead of (or, in some case, in addition to) protective layer 100.

The protective layers 100, 200 described above can provide any or all of the following advantageous features:

thermal and heat insulation;

reduce insulation space requirements;

eliminate (or minimize) need for cladding cold insulation;

fire protection and high temperature insulation with an extremely wide temperature use range from -270 °C to 1200 °C;

water repelling;

noise reduction;

eliminate corrosion issues;

resistance to physical damage;

rigid and stable when attached to an object as insulation material;

mouldable and flexible for snuggly fitting as insulation of (e.g. geometrically complex) structures; non-dusty during installation and use;

eliminate (or reduce) human health risks during installation, repair and incidental damage;

simplify recycling.

Claims

1. A protective layer for protecting a body, the protective layer comprising at least one cloth layer and at least one aerogel paste layer arranged over the at least one cloth layer.

2. A protective layer as claimed in claim 1 , wherein the protective layer

comprises two or more cloth layers with an aerogel paste layer arranged between each pair of adjacent cloth layers.

3. A protective layer as claimed in claim 1 or 2, wherein at least one of the at least one cloth layers is/are formed of a temperature resistant fibre cloth.

4. A protective layer as claimed in claim 1 , 2 or 3, wherein at least one of the at least one cloth layers is/are formed of a silicon dioxide cloth.

5. A protective layer as claimed in any preceding claim, further comprising an outer protective layer, wherein the outer protective layer is provided as an outer surface of the protective layer.

6. A protective layer as claimed in claim 5, wherein the outer protective layer is formed of a plastic, rubber or silicone rubber material.

7. A protective layer as claimed in claim 5 or 6, wherein the outer protective layer is water and/or fire resistant.

8. A protective layer as claimed in any preceding claim, wherein the aerogel paste comprises glue.

9. A protective layer as claimed in claim 8, wherein the glue is a temperature- resistant glue.

10. A protective layer as claimed in any preceding claim, wherein the aerogel paste comprises Al₂0₃ and/or Si0₂.

11. A protective layer as claimed in any preceding claim, wherein the aerogel paste comprises silicon dioxide aerogel.

12. A protective layer as claimed in any preceding claim, wherein the aerogel paste comprises one or more of: water, a coupling agent and an aqueous dispersion agent.

13. A body comprising one or more surfaces covered with a protective layer, wherein the protective layer is as claimed in any of claims 1 to 12.

14. A body as claimed in claim 13, wherein the protective layer is attached to the body with glue or an aerogel paste.

15. A body as claimed in claim 13 or 14, wherein two or more pieces of the protective layer are attached or applied to the body, and the two or more pieces of the protective layer are attached to the body in layers on top of each other, and/or the two or more pieces of the protective layer are attached to the body adjacent to each other.

16. A body as claimed in claim 15, wherein any gaps between the two or more pieces of the protective layer are filled with aerogel paste.

17. A body as claimed in any of claims 13 to 16, wherein the body is or

comprises a wall, a panel, a cylinder, a cable, a pipe, a vehicle, a building, a cabin, a compartment, a layer, a platform, a block, a brick or a plate, or an assembly of layers, platforms, blocks, bricks or plates.

18. A method of protecting one or more surfaces of a body with a protective layer, the method comprising attaching or applying one more pieces of the protective layer to the body, wherein the protective layer is as claimed in any of claims 1 to 12.

19. A method as claimed in claim 18, the method comprising attaching the

protective layer to the body with glue or an aerogel paste.

20. A method as claimed in claim 18 or 19, the method comprising attaching or applying two or more pieces of the protective layer to the body, wherein the two or more pieces of the protective layer are attached to the body in layers on top of each other, and/or the two or more pieces of the protective layer are attached to the body adjacent to each other.

21. A method as claimed in claim 20, the method comprising filling any gaps between the two or more pieces of the protective layer with aerogel paste.

22. A method as claimed in any of claims 18 to 21, the method further

comprising drying the protective layer or allowing the protective layer to dry.

23. A method as claimed in any of claims 18 to 22, wherein the body is or

24. A method of making a protective layer, the method comprising providing at least one cloth layer and applying at least one aerogel paste layer over the at least one cloth layer.

25. A method as claimed in claim 24, wherein the protective layer is as claimed in any of claims 1 to 12.

26. Use of a protective layer as claimed in any of claims 1 to 12, for insulating and/or fireproofing and/or waterproofing a body.