FIELD OF THE INVENTION The present invention relates to an insulating apparatus, particularly but not exclusively, to a fire and sound stopping insulating apparatus.

BACKGROUND Various fire stopping and/or thermal insulation devices are known. Examples of such devices have been reported on GB2462599, US20050166539 and WO2012156765. None of these devices is suitable to fit in a vehicle such as a bus or coach, particularly for a sound stopping application. It is generally expected that the engine sound should not be very high in a passenger compartment of a bus or coach. At the same time, the passenger compartment of the bus or coach is likely to require an apparatus which is able to provide protection in case there is fire in the bus. It is an object of the present invention to address the problems above.

SUMMARY

According to one aspect of the invention, there is provided an insulation apparatus comprising: a fire reflecting coating layer; a fire resistant layer wherein the fire reflecting coating layer is formed on a first surface of the fire resistant layer; an intumescent layer formed on a second surface of the fire resistant layer, the second surface being opposite to the first surface of the fire resistant layer; a sound abatement layer formed over the intumescent layer; and means for attaching the apparatus to an object, the attaching means being formed over the sound abatement layer.

The apparatus can be used for example in a coach or bus engine bay to reduce (minimise) sound escaping from the coach or bus engine bay. The apparatus is also useful in the event of an engine bay fire to stop the fire escaping into the passenger compartment. The apparatus is also capable of reducing (minimising) heat transmission for at least 30 minutes.

The apparatus may further comprise: a first non-woven insulating layer formed between the intumescent layer and the sound abatement layer; and a second non- woven insulating layer formed between the sound abatement layer and the attaching means. The non-woven insulating layers are advantageous because it provides additional spaces around the sound abatement layer. The additional spaces help to improve acoustic performance of the apparatus. The additional spaces are capable of reducing sound transmission through the apparatus and also protecting from the fire.

The fire reflecting coating layer and the fire resistant layer may be dimensioned such that ends of these layers can be wrapped around to attach to the attaching means. This arrangement helps to stop the outside moisture from entering the layers of the apparatus.

The apparatus may further comprise a plurality of pockets each comprising the layers of the apparatus. The pockets may each form a bag. Each pocket may be formed by sewing through the layers of the apparatus. Each pocket may be formed by providing a plurality of buttons through the layers of the apparatus. Forming the pockets is advantageous because each pocket can hold the ash of the intumescent material after they are being burnt. Therefore the ash of the intumescent material does not collapse to the end (bottom) of the device. The pocket arrangement thus enables to prevent fire by using the material inside each pocket which has not been collapsed to the end (bottom) of the apparatus.

The fire reflecting coating layer may comprise a host polymer material loaded with a reflective material. It will be appreciated that the term "host" relates to an original material in which subsequent materials are added. In one embodiment the host polymer material can be Silicone. The reflective material can be for example Aluminium. The reflective material may be about 20% to 70% of the host polymer material. The reflective material of the fire reflecting coating layer may be configured to abate sound. The host polymer material may be configured such that it can reduce moisture absorption. The fire resistant layer may comprise a woven fabric. The woven fabric may comprise a material including a mineral derived fibre. In one example, the mineral derived fibre can be Basalt. Basalt is non-hygroscopic and does not absorb moisture from air. Basalt is also chemically inert and therefore it does not cause any harm if corrosive liquid may enter through the fire reflecting layer.

The intumescent layer may comprise a material including un-vulcanised polymer loaded with intercalated graphite. The un-vulcanised polymer can be termed as Grafate H _x .

The sound abatement layer may comprise a material including heavy salt. The sound abatement layer contributes significantly to reduce the sound transmission through the apparatus. For example, an engine bay "bulkhead" was simulated. This was exposed to the standard sound and stopped at 39 dB. After that the apparatus with the sound abatement layer was applied to the bulkhead and was exposed to the same standard test sound. It stopped at 45dB. There is a 6 dB reduction in values which is a significant sound reduction effect. A conventional device could achieve this but with the expense of 3 or 4 times the weight to get such an increased value (which effectively reduces sound transmission). Although the sound abatement layer is the dominant layer to stop the sound transmission, the woven fabric and the intumescent material both contribute to the sound reduction.

The attaching means comprises a polyurethane (PU) coating. The PU coating can enable to attach the apparatus to a suitable object using commercially available adhesives.

The first and second non-woven insulating layers may each comprise fibres and a non- woven fabric to bind the fibres together. The first and second non-woven insulating layers may be configured to abate sound and protect the sound abatement layer from fire.

According to a further aspect of the invention, there is provided an insulation apparatus comprising: a fire resistant layer; an intumescent layer formed on the fire resistant layer; means for attaching the apparatus to an object, the attaching means being formed on the intumescent layer; wherein the apparatus comprises a plurality of pockets each comprising the fire resistant layer, the intumescent layer and the attaching means.

Each pocket may be formed by sewing through the layers of the apparatus.

Each pocket may be formed by providing a plurality of buttons through the layers of the apparatus.

Each pocket may be configured to hold on the ash of the burnt intumescent material so that the ash does not fall to the end (bottom) of the apparatus.

According to a further aspect of the present invention, there is provided a method of manufacturing an insulation apparatus, the method comprising: forming a fire resistant layer; forming a fire reflecting coating layer on a first surface of the first resistant layer; forming an intumescent layer on a second surface of the fire resistant layer, the second surface being opposite to the first surface of the fire resistant layer; forming a sound abatement layer over the intumescent layer; and forming attaching means for attaching the apparatus to an object, the attaching means being formed over the sound abatement layer.

The method may further comprise: forming a first non-woven insulating layer between the intumescent layer and the sound abatement layer; and forming a second non- woven insulating layer between the sound abatement layer and the attaching means. The method may further comprise dimensioning the fire reflecting coating layer and the fire resistant layer such that ends of these layers can be wrapped around to attach to the attaching means.

The method may further comprise forming a plurality of pockets each comprising the layers of the apparatus.

The method may further comprise forming a bag from each pocket.

The method may further comprise forming each pocket by sewing through the layers of the apparatus. The method may further comprise forming each pocket by providing a plurality of buttons through the layers of the apparatus. BRIEF DESCRIPTION OF PREFERRED EMBODIMENTS

These and other aspects of the invention will now be further described, by way of example only, with reference to the accompanying figures in which: Figure 1 illustrates a fire resistant and sound abatement apparatus;

Figure 2 illustrates a graph in which the temperature variations as a function of time in the fire and sound stopping quilt are illustrated;

Figures 3 and 4 are side views of the quilt shown in Fig. 1 ;

Figures 5 and 6 are cross sectional views of the quilt in which multiple pockets are shown; and

Figures 7 and 8 are cross sectional views of a conventional fire quilt.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS Figure 1 illustrates a fire resistant and sound abatement apparatus. The apparatus can be generally termed as a fire and sound stopping quilt 100. The quilt 100 has a laminated structure in which multiple layers are stacked. In one embodiment, the quilt 100 includes a woven fabric 105 which is, for example, coated by a coating layer 1 10. The woven fabric 105 can be made of a material such as Basalt. In one example, the Basalt material can have a weight of about 800 to 1300g/m ² , preferably about 1250 g/m ² . The coating layer 1 10 includes a Silicone coating with Aluminium colour. The coating layer 1 10 includes a +/-50% micronised Aluminium loading.

The quilt 100 further includes an intumescent material 1 15 on top of the woven fabric 105. The intumescent material 1 15 can have a thickness of about 1.8mm. In one example, the intumescent material can be un-vulcanised polymer loaded with intercalated graphite. In one example, the un-vulcanised polymer can be termed as "Grafate H _x ". The fire and sound stopping quilt 100 also includes a non-woven fabric made of fibres 120. The non-woven fabric can bind the fibres together. In one embodiment, the non- woven fabric 120 can include Basalt and can be termed as Basalt needle felt. In one example, the non-woven fabric with the fibres can be about 4 to 6 mm thick.

The fire and sound stopping quilt 100 includes an acoustic membrane 125 on top of the non-woven fabric 120. The acoustic membrane 125 enables it to reduce sound transmission through quilt 100. The acoustic membrane 125 can be made with, for example, heavy salt.

The quilt 100 further includes a further non-woven fabric 130 made of fibres on top of the acoustic membrane 125. The quilt 100 also includes a relatively thin woven fabric 135 on top of the further non-woven fabric 130. This woven fabric 135 can be made of Basalt or glass. In one embodiment, the further non-woven fabric can have a weight of about 200 to 400g/m ² , preferably about 350 g/m ² . The thin woven fabric 135 can be coated with a thin polyurethane (PU) layer. The PU layer is suitable to ease adhesion.

Referring to the structure of Figure 1 , the coating layer 1 10 on the woven fabric 105 is advantageous as it provides enhanced acoustic performance. The Aluminium content in the coating layer 110 is capable of reflecting initial heat from the fire. The Silicone material in the coating layer 1 10 is capable of providing protection from any liquid or moisture. Alternatively, the coating layer 1 10 can use Aluminium foil or PU material or polymeric coating. The Basalt woven fabric 105 adjacent the coating layer 110 has very high fire resistivity. It can generally reduce the high temperature from the fire. Therefore it can be considered as an ablative fire stopping membrane.

Referring to the intumescent layer 115, the polymer loaded with graphite can act as an active insulation barrier. The active insulation barrier can swell upon the contact of the fire. The intumescent material can expand up to 25 times of its own volume. For example, at 200°C, the intumescent material 1 15 can become about 45mm in thickness. It will be appreciated that other materials can also be used instead of the polymer loaded with graphite. Such as alternative material can be Palusol. The Palusol material can be 1.8mm thick and can expand up to 50 mm. Generally anything between about 0.5mm to 5mm initial thickness is suitable for the intumescent layer 1 15.

The non-woven fabric 120 and the associated fibres can be termed as Basalt needle felt. The thickness of the needle felt is about 4 to 6mm. The fire rating of the non-woven fabric 120 is generally very useful. Furthermore these provide additional spaces around the acoustic membrane 125. These additional spaces improve sound performance of the acoustic membrane 125. Furthermore, the non-woven fabric can protect the acoustic membrane 125 from the fire. It will be appreciated that other non-woven fabric can be used for the quilt 100, for example, Rockwool, E-Glass wool, or ceramic wool. It will be also appreciated that the non-woven fabric 120 can be sometimes referred as a slab.

In one example, the acoustic membrane 125 is a commercially available layer which is able to reduce sound transmission through the membrane 125. In one example, the acoustic membrane 125 is loaded with heavy salt to form a polymeric acoustic membrane. The acoustic membrane 125 can have a thickness of about 3 mm to 5 mm.

The thin woven fabric 135 on top of the non-woven fabric 130 has lighter weight compared to the other Basalt woven fabric 105. The thin woven fabric 130 can have a PU coating which enables the fabric 130 to be attached to a suitable object. The PU coating can be used very conveniently with commercially available adhesives. Alternatively, the thin woven fabric 135 can be made of glass cloth and it may not have any coating on the fabric 135.

In Figure 1 , the coating layer 1 10 and the Basalt woven fabric are wrapped around to all the edges of the thin woven fabric 135. This arrangement keeps the moisture (not just water) out of the fire quilt. Basalt is non-hygroscopic and therefore does not absorb moisture from air. Basalt is about 6 times less hygroscopic than glass and therefore this design prevents moisture. Furthermore, Basalt is chemically inert. Therefore if the coating layer 1 10 is penetrated and corrosive liquid goes in, it does not cause any harm.

Figure 2 illustrates a graph in which the temperature variations as a function of time in the fire and sound stopping quilt 100 are illustrated. In the structure of Figure 1 , the coating layer 1 10 is generally faced to the fire, and the thin woven fabric 135 is generally used to attach the fire quilt 100 to an object. The description of various steps of the temperature variations is presented below. At step 1 (S1), the temperature is relatively high at 200°C when the fire is faced to the quilt.

At step 2 (S2), the temperature goes down as the temperature is reflected by the coating layer 1 10 and the woven fabric 105 working as an ablative fire stopping layer provides protection from the fire.

At step 3 (S3), the temperature goes up again as the protection provided by the coated woven fabric has expired. At 200°C, the intumescent material 11 starts to expand and acts as an active insulation barrier.

At step 4 (S4), due to the expansion of the intumescent material the temperature decreases.

At step 5 (S5), the expanded intumescent material 1 15 can be completely burnt and becomes ash. At that point the temperature increases again. The non-woven fabrics 120, 130 can act as an additional barrier or passive insulation material.

Figures 3 and 4 are side views of the quilt shown in Fig. 1. The quilt includes pockets 300, 400 formed throughout the entire region of the quilt. In Figure 4, the pockets are formed by sewing the quilt. In Figure 4, the pockets are formed by providing buttons 500 throughout the quilt.

Figures 5 and 6 are cross sectional views of the quilt in which multiple pockets are shown. Figure 6 shows the scenario in which the fire has not been in contact with the quilt 100. Therefore the intumescent material has not been expanded. In Figure 6, the intumescent material has been expanded and therefore the pockets are expanded as well.

Figures 7 and 8 are cross sectional views of a conventional fire quilt. Figure 7 shows the conventional fire quilt which is not in contact with fire. Figure 8 shows the same fire quilt but after it is being in contact with the fire. The conventional fire quilt does not have any pockets throughout the fire quilt. Therefore when the intumescent material becomes ash it collapses to the bottom of the fire quilt and the expanded intumescent slumps. This is not advantageous as the collapsed slump does not provide any further fire protection. The pockets provided throughout the quilt 100 in Figures 3 to 6 solve this problem. The individual pockets can hold the ash of the intumescent material. Therefore the ash is distributed throughout the quilt. This avoids gaps in the fire protection. It will be appreciated that the components used in the fire and sound stopping quilt 100 are "Green" components. The woven fabric 105 made of Basalt does not give any gas when the fire is applied to it, and therefore this material is environmental friendly. No components requires special disposal and therefore can be added to any ordinary refuse.

Although the invention has been described in terms of preferred embodiments as set forth above, it should be understood that these embodiments are illustrative only and that the claims are not limited to those embodiments. Those skilled in the art will be able to make modifications and alternatives in view of the disclosure which are contemplated as falling within the scope of the appended claims. Each feature disclosed or illustrated in the present specification may be incorporated in the invention, whether alone or in any appropriate combination with any other feature disclosed or illustrated herein.