Fire performance composition

Abstract

The present disclosure generally relates to compositions that have fire performance properties. In particular, the present disclosure generally relates to curable fire performance compositions, cured fire- performance composites, and fire-performance articles or composite panels comprising said compositions or composites. The compositions, composites, articles, and composite panels of the present disclosure may comprise an aluminosilicate in combination with one or more additional components, including for example silicates, inorganic hydroxides, and / or water. The present application also relates to methods for the preparation of said compositions, composites, articles, composite panels as well as uses thereof.

Description

FIRE PERFORMANCE COMPOSITIONTechnical Field

[0001] The present application generally relates to compositions that have fire performance properties. In particular, the present application generally relates to curable fire performance compositions, cured fire-performance composites, and fireperformance articles or composite panels comprising said compositions or composites. The disclosure also relates to methods for the preparation of said compositions, composites, articles, composite panels as well as uses thereof.Background

[0002] Fire-resistant materials are known in the building industry, and are typically incorporated as a core in cladding or panel materials. However, current state-of-the-art fire-performance materials are deficient in various ways, for example, possess poor physical properties (e.g. mechanical strength, compression), poor weatherability (and thus cannot be used in exterior settings), exhibit little to sub-optimal fire-resistance beyond certain temperatures, and / or are produced by environmentally damaging processes.

[0003] Accordingly, there is a need for improved fire-rated compositions, which, for example, could be used in the core of cladding or panels to achieve improved fire performance, including those may be formed from waste materials, or at least a need to provide the public with alternative building panels and compositions.Summary

[0004] The present inventors have undertaken significant research into identifying and developing curable fire-performance compositions, cured fire-performance composites and fire-performance articles or composite panels comprising said compositions or composites. The curable fire-performance compositions typically comprise analuminosilicate. One or more additional components may also be present, including for example a silicate, inorganic hydroxide, and / or water. The curable fire -performance compositions may comprise an aluminosilicate, inorganic hydroxide, and optionally water. The curable fire-performance compositions may comprise an aluminosilicate, a silicate, and optionally water. The curable fire-performance compositions may comprise an aluminosilicate, a silicate, an inorganic hydroxide, and optionally water. A cured fireperformance composite may be formed by curing any of the curable fire-performance compositions described herein.

[0005] Accordingly in one aspect, the present disclosure provides for a curable fireperformance composition comprising: an aluminosilicate; a silicate; an inorganic hydroxide; and optionally, water.

[0006] In another aspect, the present disclosure provides for a curable fire performance composition consisting of: an aluminosilicate; a silicate; an inorganic hydroxide; optionally, water; and optionally one or more additives selected from the group consisting of strengthening additives, a density modifying additives, viscosity modifying additives, surfactants, and proteins.

[0007] In some embodiments, the ratio of the amount of aluminosilicate to the amount of inorganic hydroxide is between about 1:5 and about 5: 1, between about 1: 1 and about 5: 1, between about 1.2: 1 and about 4.2: 1, between about 1: 1 and about 4: 1, between about 1: 1 and about 3: 1, between about 1.5: 1 and about 2.5: 1, or about 2: 1.

[0008] In some embodiments, the aluminosilicate is present in an amount of between about 20% and about 80% of the total weight of the composition, the silicate is present in an amount of between about 5% and about 50% of the total weight of the composition, the inorganic hydroxide is present in an amount of between about 5% and about 30% of the total weight of the composition, and the water, when present, is present in an amount of between about 10% and about 35% of the total weight of the composition.

[0009] In some embodiments, the aluminosilicate is present in an amount of between about 1% and about 30% of the total weight of the composition, and the silicate is present in an amount of between about 1% and about 20% of the total weight of the composition, and the inorganic hydroxide is present in an amount of between about 2% and about 20% of the total weight of the composition, the water, when present, is present in an amount of between about 3% and about 80% of the total weight of the composition.

[0010] In some embodiments, the aluminosilicate is present in an amount of between about 20% and about 80% by weight of the composition, and the silicate is present in an amount of between about 5% and about 30% by weight of the composition, and the inorganic hydroxide is present in an amount of between about 15% and about 30% by weight of the composition.

[0011] In some embodiments, the aluminosilicate is a pozzolanic material. In some embodiments, the aluminosilicate is selected from the group consisting of slag, fly ash, metakaolin, red mud, sewage sludge and calcined clay. In some embodiments, the aluminosilicate is a slag, preferably a ferrous slag. In some embodiments, the slag selected from the group consisting of blast furnace slag, ground granulated blast furnace slag, and powdered granulated blast furnace slag.

[0012] In some embodiments, the silicate is selected from the group consisting of aluminosilicates, alkali alumina- silicates, magnesium silicates, calcium silicates, sodium silicates, and combinations thereof. In some embodiments, the silicate is a sodium silicate, preferably sodium meta silicate. In some embodiments, the sodium silicate is a refined sodium silicate. In some embodiments, the inorganic hydroxide is an alkali metal hydroxide. In some embodiments, the inorganic hydroxide is sodium hydroxide.

[0013] In some embodiments, the curable fire -performance composition further comprises a density modifying additive. In some embodiments, the density modifying additive is selected from the group consisting of proteins, hollow microspheres, and combinations thereof. In some embodiments, the density modifying additive is a hollow microsphere, preferably a glass hollow microsphere. In some embodiments, the densitymodifying additive is a glass hollow microsphere. In some embodiments, the density modifying additive is present in an amount of between about 1% and about 30% of the total weight of the composition.

[0014] In some embodiments, the curable fire performance composition further comprises a strengthening additive. In some embodiments, the strengthening additive is a fibre material, preferably wherein the strengthening additive is selected from the group consisting of polymer fibre, glass fibre, basalt fibre, or carbon fibre. In some embodiments, the strengthening additive is basalt fibre. In some embodiments, the strengthening additive is present in an amount between about 1% and about 40% by weight of the total weight of the composition.

[0015] In some embodiments, the curable fire performance composition further comprises at least one additive selected from the group consisting of: a viscosity modifying additive; a surfactant; and a protein.

[0016] In some embodiments, the curable fire performance composition does not substantially comprise cement.

[0017] In some embodiments, the curable fire performance composition further comprises water.

[0018] In some embodiments, the curable fire performance composition is deemed noncombustible under AS 1530.1-1994 or AS 1530.4-2005. In one embodiment, the curable fire performance composition is deemed non-combustible under AS 1530.1-1994. In one embodiment, the curable fire performance composition is deemed non-combustible under AS 1530.4-2005.

[0019] In some embodiments, the curable fire performance composition is the form of a slurry. In some embodiments, the curable fire performance composition is the form of a foam, optionally a hardened or set foam.

[0020] In another aspect, the present disclosure provides for a fire-performance composite comprising or consisting of a cured product of a curable fire-performance composition according to any aspect, embodiment or example described herein.

[0021] In another aspect, the present disclosure provides for a fire-performance article comprising a fire-performance composite according to any aspect, embodiment or example described herein, or a curable fire -performance composition according to any aspect, embodiment or example described herein.

[0022] In some embodiments, the fire -performance article is in the form of a panel, optionally a foam panel or a cladding panel. In some embodiments, the fire performance composition forms the core of the fire-performance article.

[0023] In another aspect, the present disclosure provides for a composite panel comprising two outer layers and a core, wherein the core comprises a fire-performance composite according to any aspect, embodiment or example described herein, or a curable fire-performance composition according to any aspect, embodiment or example described herein.Brief Description of Drawings

[0024] Exemplary embodiments of the present disclosure are described herein, by way of non-limited example only, with reference to the following drawings:

[0025] Figure 1: Variation of thermal conductivity with density for various thermal insulation materials, including KN composite foam.

[0026] Figure 2: Variation of compression strength with density for various thermal insulation materials, including KN composite foam.

[0027] Figure 3: Comparison of the thermal resistivity of KN composite foam to commercially available non-combustible thermal insulation materials: (a) glass wool; (b) mineral wool; and (c) aerated mortar.

[0028] Figure 4: Images of the KN composite foam sample before (a) and after (b) reaction to fire testing.

[0029] Figure 5: Images of the KN composite panel sample before (a) and after (b) reaction to fire testing.Description of Embodiments

[0030] The present disclosure describes the following various non-limiting embodiments, which relate to investigations undertaken to develop curable fireperformance compositions (and their cured forms).

[0031] With regards to the definitions provided herein, unless stated otherwise, or implicit from context, the defined terms and phrases include the provided meanings. Unless explicitly stated otherwise, or apparent from context, the terms and phrases below do not exclude the meaning that the term or phrase has acquired by a person skilled in the relevant art. The definitions are provided to aid in describing particular embodiments, and are not intended to limit the claimed invention, because the scope of the invention is limited only by the claims. Furthermore, unless otherwise required by context, singular terms shall include pluralities and plural terms shall include the singular.

[0032] All publications discussed and / or referenced herein are incorporated herein in their entirety.

[0033] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is solely for the purpose of providing a context for the present disclosure. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.

[0034] Throughout this specification, unless specifically stated otherwise or the context requires otherwise, reference to a single step, composition of matter, group of steps or group of compositions of matter shall be taken to encompass one and a plurality (i.e. one or more) of those steps, compositions of matter, groups of steps or groups of compositions of matter. Thus, as used herein, the singular forms “a”, “an” and “the” include plural aspects unless the context clearly dictates otherwise. For example, reference to “a” includes a single as well as two or more; reference to “an” includes a single as well as two or more; reference to “the” includes a single as well as two or more and so forth.

[0035] Those skilled in the art will appreciate that the disclosure herein is susceptible to variations and modifications other than those specifically described. It is to be understood that the disclosure includes all such variations and modifications. The disclosure also includes all of the examples, steps, features, methods, compositions, coatings, processes, and coated substrates, referred to or indicated in this specification, individually or collectively, and any and all combinations or any two or more of said steps or features.

[0036] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0037] As used herein, the term “about”, unless stated to the contrary, typically refers to + / - 10%, for example + / - 5%, of the designated value.

[0038] Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to a “second” item does not require or preclude the existence of lower- numbered item (e.g., a “first” item) and / or a higher-numbered item (e.g., a “third” item).

[0039] As used herein, the phrase “at least one of’, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of’ means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example and without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.

[0040] It is to be appreciated that certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination.

[0041] Any embodiment herein shall be taken to apply mutatis mutandis to any other embodiment unless specifically stated otherwise.

[0042] Throughout the present specification, various aspects and components of the invention can be presented in a range format. The range format is included for convenience and should not be interpreted as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range, unless specifically indicated. For example, description of a range such as from 1 to 5 should be considered to have specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 5, from 3 to 5 etc., as well as individual and partial numbers within the recited range, for example, 1, 2, 3, 4, 4.5 or 5, unless where integers are required or implicit from context. This applies regardless of the breadth of the disclosed range. Where specific values are required, these will be indicated in the specification.

[0043] The reference to “substantially free” generally refers to the absence of that compound or component in the composition other than any trace amounts or impurities that may be present, for example this may be an amount by weight % in the total composition of less than about 1%, 0.1%, 0.01%, 0.001%, or 0.0001%. The compositions as described herein may also include, for example, impurities in an amount by weight % in the total composition of less than about 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.01%, 0.001%, or 0.0001%.

[0044] All details in percentages refer to weight percentage of total dry ingredients in the composition unless otherwise indicated. For the avoidance of doubt, “dry ingredients” include but are not limited to (a) inorganic binder; (b) a silicate mineral; (c) an inorganic phosphate, (d) borate compound and (e) heat expandable solid.

[0045] The term “and / or”, e.g., “X and / or Y” shall be understood to mean either “X and Y” or “X or Y” and shall be taken to provide explicit support for both meanings or for either meaning.Specific Terms

[0046] As used herein, the term ‘curable’ refers to a composition or material having one or more components that can participate in a cure (or curing) transition and reaction that results in toughening and / or hardening of the composition or material. Due to chemical and / or physical processes, a curable composition or material may undergo changes in its physical properties over time. A curable composition or material may be curable at room temperature or lower, or may require exposure to elevated temperatures, such as temperatures above room temperature or one or more other conditions, to initiate and / or accelerate the cure transition. In some cases, a curable composition or material may require further additives (in additive to a particular temperature or one or more other conditions) in order to undergo curing.

[0047] As used herein, the term ‘cured’ refers to a composition or material having one or more components that have participated in a cure transition and reaction that resultsin toughening and / or hardening of the composition or material. It will be appreciated that the term ‘cured’ does not qualify any degree of curing, and includes a composition or material that has been partially cured.

[0048] As used herein, the term ‘fire-performance composition’ or ‘fire performance composite’ refers to a composition or composite having properties that render the composition / composite able to withstand some degree of heat exposure. Such performance may refer to the ability of the composition / composite to resist and / or retard structural and / or chemical decomposition when exposed to fire, combustion, or high temperature conditions. It will be appreciated that the term ‘fire-performance’ does not qualify in any way that the composition / composite is fire resistant or fireproof. In some cases, the composition or composite will be curable (that is to say, is not in a cured state, but is capable of being cured), and may be described as a fire performance composition or fire -performance composite, either in the sense that fireperformance properties are possessed and / or exhibited in the curable / uncured form, or in the sense that the act of exposure to fire, combustion or heat transitions the uncured / curable form to a form, e.g. at least a partially cured form, that possesses and / or exhibits fire-performance properties. In some cases, curing is performed in a manner that is deliberate (e.g. in an oven, or in air) to provide at least a partially cured form of the composition or composite, which possesses and / or exhibits fireperformance properties. As discussed, in some cases, the uncured / curable form possesses and / or exhibits fire-performance properties, which are retained, substantially retained, or improved upon some degree of curing. In some such cases, curing may be performed to provide and / or enhance structural integrity to the composition or composite. Without wishing to be bound by theory, the fire-performance of the composition / composite described herein is believed to be achieved, at least in part, through curing or at least partially curing a composition comprising the specific combination of an aluminosilicate, a silicate, and an inorganic hydroxide as described herein, which represents at least one technical contribution to the art the present disclosure provides.

[0049] The term “exposure to an elevated temperature experienced under fire conditions” is used herein to refer to severe fire conditions as simulated by heating at a temperature of at least 750°C for a period of 30 minutes. In one example, the temperature is 750°C. In one example, the temperature is 800°C.

[0050] As used herein, the term “fire-resistant” generally means a material that does not melt, ignite, or decompose up to a temperature of 250 °C at ambient atmospheric oxygen levels. “Fire-resistance” can be assessed using techniques known to the person skilled in the art. In a preferred embodiment, “fire-resistant” means “non-combustible” in accordance with AS 1530.1-1994.

[0051] All details in percentages refer to weight percentage of total dry ingredients in the composition unless otherwise indicated.Curable fire performance compositions and fire-performance composites, and methods of preparation thereof

[0052] The present disclosure provides for a curable fire-performance composition comprising: an aluminosilicate; a silicate; an inorganic hydroxide; and optionally, water.

[0053] The present disclosure also provides for a curable fire performance composition consisting of: an aluminosilicate; a silicate; an inorganic hydroxide; optionally, water; and optionally one or more additives selected from the group consisting ofstrengthening additives, density modifying additives, viscosity modifying additives, surfactants, and proteins.Composition

[0054] It will be appreciated that the amount of each particular component present in the curable fire-performance composition may be described as either as precise amount or as a range, which in either case may be an amount that is given relative to any other particular component, or an amount that is given relative to all components. For example, embodiments herein may describe a particular component of the curable fireperformance composition as being present in an amount or range of amounts, which may be given relative to all components of the composition, for example, as a percentage, or range thereof, of the total weight of the composition.

[0055] In some embodiments, the ratio of the amount of aluminosilicate to the amount of inorganic hydroxide is between about 1:5 and about 5: 1, between about 1: 1 and about 5: 1, between about 1.2: 1 and about 4.2: 1, between about 1: 1 and about 4: 1, between about 1: 1 and about 3: 1, between about 1.5: 1 and about 2.5: 1. In some embodiments, the ratio of the amount of aluminosilicate to the amount of inorganic hydroxide is about 2: 1.Aluminosilicate

[0056] It will be understood that the aluminosilicate may be any aluminosilicate. “Aluminosilicate” is a term known to persons skilled in the art, and will be understood to refer to minerals that contain a salt formed by partially substituting silicate or silicon dioxide with aluminium, and optionally may contain further substitution with other elements, such as calcium, potassium or sodium. Examples of suitable aluminosilicates include, but are not limited to, calcined clays, kaolinitic clays, lateritic clays, volcanic rocks, mine tailings, slag including blast furnace slag, coal fly ash, natural aluminosilicate materials including muscobite, beryl, decrote, sepiolite and kaolinite, and combinations thereof. In some embodiments, the aluminosilicate is a pozzolanic material. As used herein “pozzolanic material” or “pozzolan” refers to refers to naturalsiliceous or silicoaluminous substances or a combination thereof, but also fly ashes, silica fumes and materials having pozzolanic properties, such as slag-type or slag-like materials. In some embodiments, the “pozzolanic material” or “pozzolan” does not refer to cementitious materials, such as Portland cements e.g., gray or white Portland cements, pozzolanic cement, alumina cement, hydraulic lime, calcium aluminates cement, masonry cement, or mortar cement, anhydrous or hydrated gypsum (calcium sulfate), limestone, and combinations thereof, viz. is a “non-cementitious pozzolanic material”. In some alternative embodiments, “pozzolanic material” or “pozzolan” refers to a natural substance in a finely divided state which does not have water solubility by itself but can react with calcium hydroxide, Ca(OH)2, dissolved in water to slowly form a compound which does not dissolve in water.

[0057] In some embodiments, the aluminosilicate has silicon dioxide content (in %) greater than about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60. In some embodiments, the aluminosilicate has silicon dioxide content (in %) less than about 60, 55, 50, 45, 40, 35, 30, 25, 20, 15 or 10. In some embodiments, the aluminosilicate has silicon dioxide content (in %) in a range provided by any two of the previously described upper and / or lower amounts, for example, in some embodiments, the aluminosilicate has silicon dioxide content (in %) between about 10 and about 60, between about 20 and about 50, or between about 30 and about 40.

[0058] In some embodiments, the aluminosilicate has calcium oxide content (in %) greater than about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55 or 60. In some embodiments, the aluminosilicate has calcium oxide content (in %) less than about 60, 55, 50, 45, 40, 35, 30, 25, 20, 15 or 10. In some embodiments, the aluminosilicate has calcium oxide content (in %) in a range provided by any two of the previously described upper and / or lower amounts, for example, in some embodiments, the aluminosilicate has calcium oxide content (in %) between about 10 and about 60, between about 20 and about 50, or between about 30 and about 50, or between about 35 and about 45.

[0059] In some embodiments, the aluminosilicate has aluminium oxide content (in %) greater than about 5, 10, 15, 20, 25, 30, 35 or 40. In some embodiments, thealuminosilicate has aluminium oxide content (in %) less than about 40, 35, 30, 25, 20, 15, 10 or 5. In some embodiments, the aluminosilicate has aluminium oxide content (in %) in a range provided by any two of the previously described upper and / or lower amounts, for example, in some embodiments, the aluminosilicate has aluminium oxide content (in %) between about 5 and about 40, between about 5 and about 30, between about 5 and about 20, between about 5 and about 15, or between about 10 and about 15.

[0060] It will be understand that aluminosilicates that are suitable for inclusion in the curable fire-performance compositions described herein, including all possible combinations of the above described contents of silicon dioxide, a calcium oxide, and aluminium oxide. In one example, the aluminosilicate has a silicon dioxide content (in %) of between about 10 and about 60, a calcium oxide content (in %) of between about 10 and about 60, and an aluminium oxide content (in %) of between about 2 and about 20. In another example, the aluminosilicate has a silicon dioxide content (in %) of between about 30 and about 40, a calcium oxide content (in %) of between about 30 and about 50, and an aluminium oxide content (in %) of between about 8 and about 14.

[0061] In some embodiments, the aluminosilicate is selected from the group consisting of slag, fly ash, metakaolin, red mud, sewage sludge and calcined clay. In some embodiments, the aluminosilicate is a slag. As used herein, "slag" refers to the by-product of smelting ore or recycled / recyclable metals. Typically the smelting is performed to extract and / or purify a desired base metal contained within the ore or recycled / recyclable metal. Typically slag may be categorised as a ferrous, ferrous alloy or non-ferrous slag. In some embodiments, the slag is a ferrous slag or ferrous alloy slag. A ferrous slag or ferrous alloy slag is a typical by-product of the iron and / or steelmaking process. In some embodiments, the slag is blast furnace slag. In some embodiments, the aluminosilicate is a slag selected from the group consisting of blast furnace slag, ground granulated blast furnace slag, and powdered granulated blast furnace slag. In some embodiments, the aluminosilicate is a refined aluminosilicate, for example, a refined slag, or a refined blast furnace slag. "Blast furnace slag” is known to persons skilled in the art, and typically refers to the collection of impurities obtained when pig iron is produced from iron ore, limestone, coke, or the like in a blast furnace within the steel industry. As such, blastfurnace slag typically comprises compounds including CaO, SiCh, AI2O3, MnO and / or MgO, but may contain other components. Aluminosilicates, such as slag or blast furnace slag, may be produced in a refined form, with such refining occurring as a result of the processes of formation of the slag, or post-processing thereafter. Examples of refinement include, but are not limited to, compositional modification of the aluminosilicate by postprocessing, or physical refinement such as grinding. By way of example, “granulated blast furnace slag” is typically produced by quenching molten blast furnace slag in water, steam, air or a combination thereof, which typically yields a glassy granular product. “Ground granulated blast furnace slag” may, for example, be produced by grinding the quenched “granulated blast-furnace slag” (which is first dewatered, dried), in order to yield a powder of the desired fineness. Fineness may be determined by any method known in the art, for example, by determining the air permeability specific surface, e.g. via the Blaine method. In some embodiments, the ground granulated blast furnace slag has a fineness greater than about 5000, 5500, 6000, 6500, 7000, 7500, 8000, 8500, 9000, 9500 or 10000 Blaine. Fineness may also be described in terms of particle size. In some embodiments, the aluminosilicate (e.g. ground granulated blast furnace slag) has a particle size (in microns) less than about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 100. Particle size may be determined by any suitable means, such as microscopy, laser diffraction or dynamic light scattering (DES). In some embodiments, the aluminosilicate is a slag selected from the group consisting of blast furnace slag, ground granulated blast furnace slag (also abbreviated to GGBFS or GGBS), and powdered granulated blast furnace slag. In one embodiment, the slag does not substantially comprise / is substantially free of any by-product of copper extraction. In a related embodiment, the slag does not substantially comprise / is substantially free of non-ferrous slag. In some embodiments, the slag has a copper oxide content (in % w / w) less than about 40, 30, 20, 15, 10, 5, 4, 3, 2 or 1. In some embodiments, the slag has a ferrous oxide content (in % w / w) less than about 40, 30, 20, 15, 10, 5, 4, 3, 2 or 1.

[0062] In some embodiments, the curable fire -performance composition comprises the aluminosilicate in an amount of at least about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the total weight of the composition. In some embodiments, the curable fire -performance compositioncomprises the aluminosilicate in an amount of at most about 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 1% of the total weight of the composition. In some embodiments, the curable fire -performance composition comprises the aluminosilicate in an amount in a range between any of the previously described upper and / or lower amounts, for the example, the curable fire -performance composition comprises the aluminosilicate in an amount between about 1% and about 80%, between 20% and about 80%, or between about 1% and about 30%.Silicate

[0063] It will be understood that the silicate is in addition to the aluminosilicate. In some embodiments, the silicate is a silicate mineral. In some embodiments, the silicate mineral is selected from the group consisting of an aluminosilicate, an alkali alumina- silicate, a magnesium silicate, a calcium silicate, a sodium silicate, and combinations thereof. In one example, the silicate mineral is a sodium silicate. In another example, the silicate mineral is sodium metasilicate. In some embodiments, the silicate is a refined silicate, for example refined sodium silicate. Examples of refinement include, but are not limited to, compositional modification of the silicate by post-processing or purification, or physical refinement such as grinding. For example, in some embodiments, the silicate (e.g. sodium silicate) has a purity (%) greater than about 80, 85, 90 or 95. In some embodiments, the silicate has a particle size (in microns) less than about 1000, 800, 600, 400, 200 or 100. It will be understand that silicates of particle size may aid dissolution and / or dispersing of the silicate during mixing of the ingredients to form the composition.

[0064] In some embodiments, the curable fire -performance composition comprises the silicate in an amount of at least about 1%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, or 50% of the total weight of the composition. In some embodiments, the curable fire-performance composition comprises the silicate in an amount of at most about 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 1% of the total weight of the composition. In some embodiments, the curable fire-performance composition comprises the silicate in an amount in a range between any of the previously described upper and / or lower amounts, for the example, the curable fire -performance compositioncomprises the silicate in an amount between about 1% and about 50%, between about 5% and about 50%, between about 1% and about 20%, between about 5% and about 30%.Inorganic hydroxide

[0065] In some embodiments, the inorganic hydroxide is a metal hydroxide. Examples of metal ions include, but are not limited to, sodium, calcium, aluminium, magnesium, barium, caesium, cobalt, iron, lead, manganese, nickel, rubidium, strontium and zinc. In some embodiments, the inorganic hydroxide is an alkali metal hydroxide. Examples of alkali metal hydroxides include, but are not limited to, sodium hydroxide, potassium hydroxide, and lithium hydroxide. In some embodiments, the inorganic hydroxide is sodium hydroxide.

[0066] In some embodiments, the curable fire -performance composition comprises the inorganic hydroxide in an amount of at least about 2%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, or 40% of the total weight of the composition. In some embodiments, the curable fire-performance composition comprises the inorganic hydroxide in an amount of at most about 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, 2% of the total weight of the composition. In some embodiments, the curable fire -performance composition comprises the inorganic hydroxide in an amount in a range between any of the previously described upper and / or lower amounts, for the example, the curable fire -performance composition comprises the inorganic hydroxide in an amount between about 2% and about 40%, between about 5% and about 30%, between about 2% and about 20%.Water

[0067] In some embodiments, the curable fire -performance composition further comprises water. The curable fire -performance composition comprises the water in an amount of at least about 3%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, or 80% of the total weight of the composition. In some embodiments, the curable fire-performance composition comprises the water in anamount of at most about 80%, 75%, 70%, 65%, 60%, 65%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, or 3% of the total weight of the composition. In some embodiments, the curable fire-performance composition comprises the water in an amount in a range between any of the previously described upper and / or lower amounts, for the example, the curable fire-performance composition comprises the water in an amount between about 3% and about 80%, or between about 10% and about 35%.Example Compositions

[0068] It will be appreciated that the amounts of each component present in the curable fire-performance composition may be independently varied according to the above descriptions, and the resultant curable fire-performance composition still exhibit suitable fire-performance properties. Accordingly, it will be understood that any and all possible combinations of the above cited amounts, or ranges thereof, of aluminosilicate, silicate and inorganic hydroxide is suitable for composing a curable fire -performance composition of the present disclosure.

[0069] In one example, the aluminosilicate is present in an amount of between about 20% and about 80% of the total weight of the composition, the silicate is present in an amount of between about 5% and about 50% of the total weight of the composition, the inorganic hydroxide is present in an amount of between about 5% and about 30% of the total weight of the composition, and the water, when present, is present in an amount of between about 10% and about 35% of the total weight of the composition.

[0070] In another example, the aluminosilicate is present in an amount of between about 20% and about 50% of the total weight of the composition, the silicate is present in an amount of between about 15% and about 30% of the total weight of the composition, the inorganic hydroxide is present in an amount of between about 15% and about 30% of the total weight of the composition, and the water, when present, is present in an amount of between about 20% and about 25% of the total weight of the composition.

[0071] In another example, the aluminosilicate is present in an amount of between about 20% and about50% of the total weight of the composition, the silicate is present in an amount of between about 15% and about 30% of the total weight of the composition, the inorganic hydroxide is present in an amount of between about 15% and about 30% of the total weight of the composition, and water is present in an amount of between about 20% and about 25% of the total weight of the composition.

[0072] In one example, the aluminosilicate is present in an amount of between about 1% and about 30% of the total weight of the composition, and the silicate is present in an amount of between about 1% and about 20% of the total weight of the composition, and the inorganic hydroxide is present in an amount of between about 2% and about20% of the total weight of the composition, and the water, when present, is present in an amount of between about 3% and about 80% of the total weight of the composition.

[0073] In one example, the aluminosilicate is present in an amount of between about 5% and about 30% of the total weight of the composition, and the silicate is present in an amount of between about 2% and about 20% of the total weight of the composition, and the inorganic hydroxide is present in an amount of between about 2% and about20% of the total weight of the composition, and the water, when present, is present in an amount of between about 20% and about 80% of the total weight of the composition.

[0074] In one example, the aluminosilicate is present in an amount of between about 5% and about 30% of the total weight of the composition, and the silicate is present in an amount of between about 2% and about 20% of the total weight of the composition, and the inorganic hydroxide is present in an amount of between about 2% and about 20% of the total weight of the composition, and the water is present in an amount of between about 20% and about 80% of the total weight of the composition.

[0075] In one example, the aluminosilicate is present in an amount of between about 20% and about 80% by weight of the composition, and the silicate is present in an amount of between about 5% and about 30% by weight of the composition, and the inorganic hydroxide is present in an amount of between about 15% and about 30% by weight of the composition.

[0076] In one example, the aluminosilicate is present in an amount of between about 20% and about 50% by weight of the composition, and the silicate is present in an amount of between about 15% and about 30% by weight of the composition, and the inorganic hydroxide is present in an amount of between about 15% and about 30% by weight of the composition.Additives / other components

[0077] One or more density modifying additives may be comprised by the curable fireperformance composition, in an amount suitable to alter the overall density of the curable fire-performance composition, or a portion thereof.

[0078] In some embodiments, the curable fire -performance composition further comprises a density modifying additive. In some embodiments, the curable fireperformance composition further comprises one or more density modifying additives. In some embodiments, the density modifying additive is selected from the group consisting of proteins, hollow microspheres, microparticles, nanoparticles and combinations thereof. In some embodiments, the density modifying additive is a hollow microsphere, optionally a glass hollow microsphere. Hollow microspheres are typically formed at high temperatures, and generally possess a higher resistance to the temperatures incurred during a fire, than that of materials that haven't been exposed to such temperatures during formation. In some embodiments, the hollow microspheres are selected from the group consisting of glass hollow microspheres, cellulose hollow microspheres, polymer hollow microspheres, or ceramic hollow microspheres. In one embodiment, the hollow microspheres are naturally generated hollow microspheres (e.g. are generated in the waste stream of coal fired power stations, for example, fly ash). Alternatively, the hollow microspheres could be synthetic microspheres or commercially available microspheres. Synthetic microspheres may be formed deliberately through blending of raw materials to form a precursor, generally either a glass melt that is ground to fine particles, or a solution that is spray-dried to form fine particles. In some embodiments, the density modifying additive is a glass hollow microsphere. In some embodiments, the density modifying additive is a protein. Examples of suitable proteins include, but are not limited to, dairy based proteins, plant based proteins, animal based proteins or artificial proteins, or combinations thereof. Further examples include egg based proteins or bovine based proteins.

[0079] In some embodiments, the density modifying additive is distributed homogeneously within the curable fire performance composition. In other embodiments, the density modifying additive is distributed heterogeneously within the curable fire performance composition. In a further embodiment, the performance of the fire performance composite or article can be tailored to provide optimized functional effectiveness in different portions of the fire performance composite or article by having the at least one density modifying additive distributed preferentially. For example, having a density gradient through the thickness of the fire resistant body, the body canprovide a dense portion which provides the best weather resistance for an exterior building panel face, and a density modified portion where weather resistance is not a performance criteria. This is particularly the case when no additional layer is used, and the second major face of the fire resistant body provides an exterior durable surface of the fire performance composite, article (e.g. panel).

[0080] In certain embodiments, the hollow microspheres (e.g. hollow glass microspheres) have a density (in g / cm3) of less than about 2.0, 1.8, 1.6, 1.4, 1.2, 1.0, 0.8, 0.6, 0.4, or 0.2.

[0081] In some embodiments, the density modifying additive (for example, glass hollow microspheres) is present in an amount of between about 1% and about 30%, between about 2% and about 30%, between about 5% and about 25%, or between about 10% and about 20%, of the total weight of the composition. In some embodiments, the density modifying additive (for example, glass hollow microspheres) is present in an amount of between about 1% and about 30% of the total weight of the composition. In some embodiments, the density modifying additive (for example, glass hollow microspheres) is present in an amount of between about 10% and about 20% of the total weight of the composition.

[0082] In some embodiments, the curable fire -performance composition further comprises a strengthening additive. In some embodiments, the strengthening additive is a fibre material. In some embodiment, the fibre material is selected from the group consisting of natural organic fibres, synthetic organic fibres, and synthetic inorganic fibres. In some embodiments, the strengthening additive is selected from the group consisting of polymer fibre, glass fibre, basalt fibre, or carbon fibre. In some embodiments, the strengthening additive is polymer fibre. In some embodiments, the strengthening additive is basalt fibre. In some embodiments, the strengthening additive is carbon fibre. Other suitable fibre materials include metal fibres, refractory fibres, ceramic fibres, synthetic fibres, non-organic fibres, and naturally-derived fibres.

[0083] Strengthening additives may be included in the composition in order to provide additional mechanical strength and / or reinforcement to the composition and / or cured composite. In some embodiments, the strengthening additive (e.g. basalt fibre) is present in an amount of between about 1% and about 40%, between about 2% and about 30%, between about 5% and about 20%, or between about 5% and about 10%, of the total weight of the composition. In some embodiments, the strengthening additive (e.g. basalt fibre) is present in an amount of between about 1% and about 40%. In some embodiments, the strengthening additive (e.g. basalt fibre) is present in an amount of between about 5% and about 10%, of the total weight of the composition.

[0084] In some embodiments, the curable fire -performance composition further comprises at least one additive selected from the group consisting of: a viscosity modifying additive; a surfactant; and a protein.

[0085] Viscosity modifying additives may be added to curable fire-performance compositions to modulate the thickness of the mixture, improve stability (e.g. foaming stability), and improve attachment of the composition to surfaces while the composition is wet. In some embodiments, the curable fire-performance composition further comprises a viscosity modifying additive. In some embodiments, the viscosity modifying additive is selected from the group consisting of polysaccharides, starches, thixotropic agents, polymers, and clays. In some embodiments, the viscosity modifying additive is present in an amount of between about 0.1% and about 10% of the total weight of the composition. In some embodiments, the viscosity modifying additive is present in an amount of about 1% and about 10% of the total weight of the composition.

[0086] Suitable polysaccharides include, but are not limited to, cellulose, starch, pectin, chitin, gum (e.g. Xanthan gum). Suitable starches include, but are not limited to com starch, potato starch, wheat starch, rice starch, cassava starch, tapioca starch, and arrowroot starch. Suitable thixotropic agents include, but are not limited to, polyvinylpyrrolidone, titanate coupling agents, metal soaps (such as calcium stearate,aluminium stearate, and barium stearate, aluminium distearate, and aluminium tristearate), copolymers with acidic groups, compounds having ionic groups, fumed silica, colloidal silica, asbestine, organic derivatives of castor oil (such as hydrogenated castor oil derivatives), treated clays, organic bentonite, modified polyester polyols (such as polyoxyethylene-polyoxypropylene block copolymers), aliphatic amides, and polyamides (such as polyamide waxes). Suitable polymers include, but are not limited to, polystyrene, polyolefins (e.g. polyethylene, polypropylene), polycarbonates, polyphenylene oxides and mixtures thereof.

[0087] The addition of a surfactant and / or protein to the curable -performance composition may facilitate modulation of density (as previously described for protein), modulate thermal conductivity, and / or increase noise absorption properties of the composition and cured composite.

[0088] In some embodiments, the curable fire-performance composition further comprises a surfactant. Suitable surfactants include, but are not limited to, non-ionic, anionic, cationic or zwitterionic surfactants, or combinations thereof. Further suitable surfactants include, but are not limited to, include sodium polyacrylate dispersants, ethoxylated non-ionic compounds, alkyl ether sulfates (e.g. Vinapor GYP 2620) and other surfactants known to those of ordinary skill in the art.

[0089] In some embodiments, the curable fire -performance composition further comprises a protein. In some embodiments, the curable fire-performance composition further comprises a protein based surfactant. The person skilled in the art will appreciate that there is no particular limitation as to proteins that may be included in the curable fire-performance composition. Examples of suitable proteins include, but are not limited to, dairy based proteins, plant based proteins, animal based proteins or artificial proteins, or combinations thereof. Further examples include e.g. based proteins or bovine based proteins.

[0090] In some embodiments, the curable fire-performance composition does not substantially comprise cement. In some embodiments, the curable fire-performancecomposition comprises less than 50%, 40%, 30%, 20%, 10%, 5%, 3%, 2%, 1% or 0.1% cement, by total weight of the composition. In some embodiments, the curable fireperformance composition comprises less than 10%, 1% or 0.1% cement, by total weight of the composition.Forms

[0091] It will be appreciated that any of the curable fire -performance compositions described herein may exist in a variety of forms, for example, as a solid, a powder, a liquid, a slurry, a suspension, a paste, a foam, or a gel. In some embodiments, the form of the curable fire -performance composition is dry, for example as a dry powder or dry solid, such as a dry amorphous solid. In some embodiments, the curable fire-performance composition is in the form of a slurry or a foam. In some embodiments, the curable fireperformance composition is in the form of a slurry. In some embodiments, the curable fire-performance composition is in the form of a foam, optionally a hardened or set foam. In some embodiments, the foam is a hardened or set foam.Fire performance composites

[0092] It will be appreciated that the curable fire -performance composition may be ‘cured’ or subjected to a (directed or spontaneous) curing process, in order to form a cured product. Accordingly, the present disclosure also provides for a fire-performance composite comprising or consisting of a cured product of a curable fire -performance composition according to any aspect, embodiment, or example disclosed herein.

[0093] In some embodiments, the cured product is formed by air curing, heat curing, steam curing or autoclave curing. In some embodiments, the cured product is formed by air curing or heat curing. In some embodiments, the cured product is formed by air curing. In some embodiments, the cured product is form by heat curing.Methods of preparation

[0094] In another aspect, the present disclosure provides for a method of preparing a curable fire-performance composition according to any aspect, embodiment, or example described herein.

[0095] The components of a curable fire-performance composition may be combined in any order. In some embodiments, the method comprises contacting the aluminosilicate, hydroxide, and silicate, optionally water, and optionally one or more additives.

[0096] In some uses it may be desirable to form a dry composition, which may stored until time of use, whereupon water may be added to ready the composition for curing. Thus, in some embodiments, the method comprises contacting the aluminosilicate, hydroxide, and silicate to provide a dry intermediate. In a particular example, the dry intermediate is optionally contacted with one or more additives (e.g. density modifying additive). In some embodiments, the method comprises one or more steps of mixing, for e.g. mixing the dry intermediate, or mixing the dry intermediate following addition of the one or more additives.

[0097] For other uses, it may be desirable to form a wet composition (e.g. when immediate foaming and / or curing is desired). Thus, in some embodiments, the method comprises contacting the aluminosilicate, hydroxide, and silicate, water, and optionally one or more additives. In other embodiments the components of the curable-fire performance composition may be combined in a particular order, e.g. by combing one or more compositions in a particular order and / or manner.

[0098] In some embodiments, the method comprises contacting a first composition with a second composition, optionally with mixing, wherein: the first composition comprises the aluminosilicate, silicate, hydroxide, and water; and the second composition comprises water and a density modifying agent.

[0099] In a particular example thereof, the second composition further comprises a viscosity modifying additive, and a surfactant.

[0100] In some examples thereof, the second composition is brought into contact with the first composition by incremental addition, optionally with mixing.

[0101] In some embodiments, the method comprises contacting the aluminosilicate and density modifying additive, optionally with mixing, to provide a dry density modified intermediate. In a particular example thereof, the method further comprises contacting the dry density modified intermediate with water, silicate and hydroxide, optionally with mixing.

[0102] It will be understood that any of above embodiments relating to a method of preparation of a curable fire-performance composition may comprise one or more mixing steps. Thus, in some embodiments, the method further comprises one or more mixing steps. In some embodiments, at least one mixing step is high shear mixing.

[0103] In another aspect, the present disclosure provides for a method of preparing a fire-performance composite comprising curing a fire-performance composition according to any aspect, embodiment, or example described herein.

[0104] In some embodiments, the method further comprises providing a curable fireperformance composition. In some embodiments, the curable fire -performance composition is prepared according to any aspect, embodiment, or example described herein. In some embodiments, the method comprises one or more curing steps. In some embodiments, the curing is air curing, heat curing, steam curing or autoclave curing, or a combination thereof. In some embodiments, the curing is air curing or heat curing, or a combination thereof. In some embodiments, the curing is air curing. In some embodiments, the curing is heat curing.

[0105] Curing may be performed with the curable fire-performance composition in a mould (including a frame or framework) and the like, which may be made of any suitablematerial (e.g. Teflon, ceramic, wood). Accordingly, in some embodiments, the method comprises transferring the composition(s) and / or components thereof into a mould. Following curing, the fire-performance composite is removed from the mould. Optionally, the mould-containing composition is placed in a container or bag prior to curing. Optionally, the container or bag is sealed.

[0106] Curing may be performed in the open air (inside or outside) or in an oven. It will be understood that curing may be performed (or allowed to occur spontaneously) at a defined temperature, pressure, and duration.

[0107] In some embodiments, the curing occurs at a temperature of at least about (in °C) 20, 25, 30, 40, 45, 50, 55, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250 or more. In some embodiments, the curing occurs at a temperature of less than about (in °C) 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 55, 50, 45, 40, 35, 30, 25, 20 or less. In some embodiments, the curing occurs at a temperature in a range provided by any two of the previously described upper and / or lower amounts, for example, the curing occurs at a temperature (in °C) between about 20 and about 250, between about 20 and about 150, between about 20 and about 100, between about 20 and about 80, between about 20 and about 70, between about 30 and about 60 or between about 40 and about 60. The person skilled in the art will appreciate that curing is dependent in part upon the duration for which the composition is at a particular temperature, such that curing may be effected at higher temperatures over shorter durations, or at lower temperatures over longer durations. For example, curing may occur over 12 to 24 hours at a temperature in between 40 and 60 °C, or curing may occur over a period less than 12 hours at elevated temperatures, such as temperatures experienced in a furnace (e.g. in excess of 60 °C) or even upon exposure to flame (e.g. in a fire, which may be in excess or well in excess of 250 °C).

[0108] In some embodiments, the curing occurs at a temperature of at least or about (in °C) 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59 or 60. In someembodiments, the curing occurs at a temperature of (in °C) between about 40 and 60. In some embodiments, the curing occurs at room temperature. In some embodiments, the curing occurs at ambient temperature.

[0109] In some embodiments, the curing occurs over a duration (in hours) of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 or 24. In some embodiments, the curing occurs over a duration (in days) of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 or 31. The person skilled in the art will appreciate that curing will occur over a duration that is influenced by the physical dimensions of the composite being prepared, and the type of mould being used. For example, a thin sheet will cure faster than a thicker sheet, or moulds that only allow moisture transportation on one surface will cure slower than moulds that allow moisture transportation on multiple surfaces.

[0110] In some embodiments, where the method comprises more than one curing step, each curing step may be at an independently selected defined temperature and duration. Furthermore, in some embodiments, where the method comprises more than one curing step, the method further comprises providing one or more intermediate composites. In some particulars examples thereof, the method comprises contacting an intermediate composite with water for a period of time (e.g. 1, 2, 3, or 4 hours). The person skilled in the art will appreciate that during an initial period of curing (for example, 24 hrs), the composition will transition to a partially or predominantly cured composite. Submersion of such an intermediate composite may optionally be performed to ensures proper hydration of the material such that it may continue to cure towards a substantially completely cured or completely cured composite, which may occur at a slower rate (relative to the initial curing) over a subsequent time period (e.g. 28 days).Fire Performance

[0111] It will be appreciated that the curable fire-performance compositions and fireperformance composites described according to any of the aspects, embodiments, or examples of this disclosure, may exhibit properties associated with fire-resistance or fire-performance. It will also be appreciated that fire -performance articles or composite panels comprising or consisting of a curable fire-performance composition(s) or fireperformance composite(s), may also exhibit fire -performance properties that are the same or similar to those of the comprised curable fire -performance composition(s) or fire-performance composite(s).

[0112] In some embodiments, the curable fire-performance composition or fireperformance composite is a fire resistant composition. For example, in some embodiments, the curable fire-performance composition does not melt, ignite, or decompose below a temperature of 250 °C at ambient atmospheric oxygen levels. In some embodiments, the curable fire -performance composition does not melt, ignite, or decompose below a temperature of 350 °C, 450 °C, 550 °C, 650 °C or 750 °C at ambient atmospheric oxygen levels.

[0113] In some embodiments, the curable fire -performance composition is a noncombustible composition. In one example, the curable fire -performance composition meets the requirements of AS 1530.1, for example AS 1530.1-1994. In some embodiments, the curable fire-performance composition is deemed non-combustible under AS 1530.1-1994. In some embodiments, the curable fire-performance composition is deemed non-combustible under AS 1530.4-2005. In one example, the curable fireperformance composition meets the requirements of ISO 1182.

[0114] Likewise, in some embodiments the fire-performance composite does not melt, ignite, or decompose up to a temperature of 250 °C at ambient atmospheric oxygen levels. In some embodiments, the fire-performance composite does not melt, ignite, or decompose up to a temperature of 350 °C, 450 °C, 550 °C, 650 °C or 750°C at ambient atmospheric oxygen levels. In some embodiments, the fire-performance composite is a non-combustible composition. In one example, the fire -performance composite meets the requirements of AS 1530.1, for example AS 1530.1-1994. In some embodiments, the fire-performance composite is deemed non-combustible under AS 1530.1-1994. In some embodiments, the fire -performance composite is deemed non-combustible under AS1530.4-2005. In one example, the fire-performance composite meets the requirements of ISO 1182.Fire performance articles

[0115] The curable fire-performance compositions and fire -performance composites described herein can be used for fire barrier applications. Examples of such applications include composite panels and barrier coatings on various applications. Accordingly, the present disclosure also provides for a fire-performance article comprising a fireperformance composite according to any aspect, embodiment or example disclosed herein, or a fire-performance composition according to any aspect, embodiment or example disclosed herein.

[0116] In some embodiments, the fire -performance article is in the form of a panel, cladding, screen, or coated substrate. In some embodiments, the fire performance composite or curable fire-performance composition forms the core of the fireperformance article. It will be appreciated that for a fire -performance article of a particular form, it may be preferable for the fire -performance composite or curable fireperformance composition to be in a particular form (e.g. a foam).

[0117] In some examples, the fire-performance article is in the form of cladding and the curable fire-performance composition or fire-performance composite forms the core of cladding. For example, the cladding may be in the form of a coated substrate, wherein the substrate is provided by an outer layer as described below comprising a coating thereon of the curable fire -performance composition or fire-performance composite as described herein.

[0118] In some embodiments, the fire -performance article is in the form of a panel, optionally a foam panel or a cladding panel. In some embodiments, the fire -performance article is in the form of a foam panel or a cladding panel. In some embodiments, the fireperformance article is in the form of a foam panel. In some embodiments, the fireperformance article is in the form of a cladding panel.Composite panels

[0119] The present disclosure also provides for a composite panel comprising two outer layers and a core, wherein the core comprises a fire-performance composite according to any aspect, embodiment or example disclosed herein, or a fire-performance composition according to any aspect, embodiment or example disclosed herein.

[0120] In some embodiments the core comprises a fire-performance composite according to any aspect, embodiment or example disclosed herein, or a fire -performance composition according to any aspect, embodiment or example disclosed herein. In some embodiments the core consists of a fire-performance composite according to any aspect, embodiment or example disclosed herein, or a fire -performance composition according to any aspect, embodiment or example disclosed herein. In a particular example, the core comprises a fire-performance composite comprising or consisting of a cured product of a curable fire -performance composition in the form of a foam, optionally a hardened or set foam (viz. the fire-performance composite is in the form of a hardened or set foam).

[0121] The two outer layers may be substantially opposing (e.g. parallel) each other such that the core is defined there between. The outer layers have an inner and outer surface. The inner surface is in contact with the core composition. The outer layers of the composite panel can be in the form of a foil, film, sheet, strip or plate shaped material. The outer layers can be manufactured from any suitable material. As would be understood by the person skilled in the art, a suitable material would preferably be noncombustible and meet the required standard (for example, AS1530.1). In some embodiments, the material may be metallic, for example a metal or metal alloy. The metal may be any metal used in the art. Suitable metals include, but are not limited to, iron, steel, zinc, tin, zinc coated iron, copper, bronze, aluminium and aluminium alloy. In one example, the outer layers of the composite panel are manufactured from aluminium or an aluminium alloy. Although it is possible that the two outer layers are manufactured from different materials, in some embodiments, the two outer layers are manufactured from the same metal.

[0122] In some embodiments, the two outer layers may be joined to the core by an adhesive or bonding agent. As would be understood by the person skilled in the art, the adhesive or bonding agent would preferably be non-combustible and meet the required standard. In some embodiments, the adhesive or bonding agent is sodium silicate or potassium silicate. In one embodiment, the inner surface of the outer layer has a coating of sodium silicate, which acts as an adhesive between the inner surface of the outer layer and the cladding composition. Sodium silicate, commonly known as "water glass" is a versatile, inorganic chemical made by combining various ratios of sand and soda ash (NaiCCh). The ratios of sand and soda ash can be varied to vary the chemical and physical properties. In one example, a sodium silicate solution (e.g., 35 % NaiSiCh solution in water) can be applied to the inner surface by a brush or other application device. In some examples, the inner surface of the outer layer can be scratched or roughened, and then cleaned with a solvent (e.g., isopropanol) prior to applying the adhesive or binding agent (e.g. sodium silicate) to allow for better adhesion. The outer layers are allowed to dry (although there needs to be some residual water in the sodium silicate to enable adhesion) before being contacted with the fire-performance composite or curable fire-performance composition. The fire-performance composite can be pre-formed (e.g. as a panel or sheet) of formed on the outer layer. If under the given conditions, the fire-performance composite exhibits adequate bonding properties, then it may be bonded directly to the outer layers. For example, the two outer layers may be joined to the core by components of the fire -performance composite or curable fire-performance composition.

[0123] The outer layers can a have thickness of between 0.1 and 5 mm. In some embodiments, the thickness of the outer layers is between 0.1 and 3 mm, for example between 0.3 and 2 mm, or between 0.5 and 1.25 mm. In some embodiments, the thickness of the outer layers is 0.5 and 1.25 mm for aluminium or aluminium alloy outer layers. The thickness of the two outer layers may be the same or different.

[0124] In some embodiments, the composite panel further comprises one or more liners. In some embodiments, a first and a second liner sandwich the core. In yet other embodiments, a liner is embedded within the core. In some embodiments, the liner is aglass webbing or fibre glass webbing. The liner can provide additional strength to the core and / or can assist in the manufacture of the composite panel core.

[0125] In some embodiments the composite panel, has a total thickness (including the thickness of the outer layers and the core) of between 2 mm and 150 mm, for example between about 10 mm and about 100 mm, between about 10 mm and about 50 mm, or between about 20 mm and about 40 mm. At this thickness, the composite panels are relatively lightweight and thus are easy to handle. This provides an advantage in view of the assembling process on building sites, especially in the case of an application as facade panels.

[0126] In some embodiments, the composite panel further comprises a printed layer coating on an outer surface of at least one of the two outer layers. A printed layer coating can be customised based on the needs of the end user. In some embodiments, the outer surface of at least one of the two outer layers is spray -painted or coated with a sticky foil.

[0127] In some embodiments, the composite panel further comprises a protective layer applied on the outer surface of one or two of the outer layers. Any suitable protective layer may be used. The protective layer can protect the composite panel from environment factors, such as ultraviolet radiation or extreme weather conditions. In some embodiments, the protective layer can be permanently fixed to the composite panel. In alternative embodiments, the protective layer can be temporarily attached to the composite panel to provide protection as long as the panels are not mounted.

[0128] The composite panels are suitable for use, for example, as building materials, facade panels, cladding on building constructions, dividing walls in buildings, in vehicle manufacture, ship building, and in equipment and machine manufacture. Preferably, the composite panels are used as facade panels, cladding on building constructions, or dividing walls in buildings, vehicles and ship structures. In one example, the composite panels are used as facade panels or cladding on building constructions.

[0129] The present application claims priority from Australian Provisional Patent Application No. 2024901157 filed on 24 April 2024, the entire contents of which are incorporated herein by reference.

[0130] In order that the disclosure may be more clearly understood, particular embodiments of the invention are described in further detail below by reference to the following non-limiting experimental materials, methodologies and examples.ExamplesExample 1 — Preparation of dry “premix” curable fire-performance composition and use thereof

[0131] A dry curable fire-performance composition was formed by combining slag (350 g), powdered sodium hydroxide (175 g) and powdered sodium silicate (175 g), and mixing. Desired additives may be added at this stage to the composition and mixed. The composition can be stored for use at a later date.

[0132] The dry composition was used by decanting the same into a container, an amount of water (225 g) added, and the suspension mixed until homogeneous, and left to set.Example 2 — Preparation of fire-performance composite foam and curing thereof

[0133] A first composition was prepared by combining slag (GGBFS, 12.5 g), water (8.75 g), and sodium hydroxide (6.25 g in solution), and mixing thoroughly. To this was added sodium silicate (6.25 g in solution) and the solution mixed thoroughly. Hollow glass microspheres (8.00 g) were added gradually whilst mixing.

[0134] A second composition was prepared separating by combining xanthan gum (0.90 g) and water (80.0 g). The solution was allowed to bloom for 10 minutes. To this was added a surfactant (Vinapor; 0.60 g), and the solution mixed for approximately 15 seconds at approximately 1000 rpm to initiate foaming. Hollow glass microspheres (12.0g) were added incrementally, interspersing with periodic mixing of the mixture for 30 seconds at 1000 rpm each time, until all hollow glass microspheres were added. The foam was observed to be thick, and not runny. This foamed second composition may be set aside for later use.

[0135] To form the composite wet foam, incremental additions of the foamed second composition were made to the first composition. About 10 to 20% of the foamed second composition was added to the first composition with each addition, with each addition followed by gentle mixing until combined. Additions of approximately 20% of the foamed second composition are recommended to decrease the density of the mixture, and result in fewer negative effects on the wet foam stability. Soft mixing is also preferred, in order to maximise preservation of the foam cells. Once addition is complete, the composite wet foam is ready for casting and curing.

[0136] A suitable mould is pre -prepared by lining a mould with a non-stick Teflon release (which controls release of moisture from the foam during curing, and facilities easier separation of the cured composition from the mould). The composite wet foam may be poured into a prepared mould, the mould placed on a breather cloth on a tray, and then transferred to an oven at approximately 40 to 60 °C for curing for a period of 12 to 24 hours. The cured hardened foam is then carefully removed from the mould.Example 3 - Preparation of fire-performance composite panel and curing thereof

[0137] A curable fire-performance composition was formed by mixing basalt fibres (70 g) and slag (350 g) in a Hobart mixture (a similar high-shear mixer will also suffice). Water (245 g), sodium silicate (175 g in solution) and sodium hydroxide (175 g in solution) were added, and mixed for a further 5 minutes, to form a curable fireperformance composition.

[0138] The curable fire-performance composition was decanted into a pre-prepared mould lined with non-stick Teflon release (or polymer film), ensuring that fibres appeared to be evenly distributed within the mould. The mould was then transferred to aplastic bag, sealed, and left to cure for 24 hours. The composite was then removed from the mould, submerged in water for 2 hours, returned to the plastic bag, sealed, and left to continue curing for a further 28 days to obtain a cured panel.Example 4 — Physical Properties Performance Assessment

[0139] The physical properties of the fire-performance foam composite were examined, and are reported in Table 1. Two cured foam composites (KNCF1 and KNCF2) were prepared consistent to the above described method. The composition of KNCF1 includes: GGBFS (37.5 g), water (236.25 g), sodium hydroxide (18.75 g), sodium silicate (18.75 g), surfactant (1.58 g), xanthan gum (2.36 g) and hollow glass microspheres (49.5 g). The composition of KNCF2 includes: GGBFS (37.5 g), water (176.25 g), sodium hydroxide (18.75 g), sodium silicate (18.75 g), surfactant (1.13 g), xanthan gum (2.36 g) and hollow glass microspheres (40.5 g). Density was tested according to ASTM D 1622, compression properties according to ASTM D 1621, flexural properties according to ASTM C 203 and combustibility in reference to AS 1530.1.Table 1. Summary of physical properties'This is the average value obtained from multiple measurements. Variations of all measured samples do not exceed 5% of the average value.2This is the average value obtained from multiple measurements. Variations of all measured samples do not exceed 25% of the average value.

[0140] To assess the relative performance of the fire -performance composite foam a comparative assessment was conducted. The necessary data relating to the thermal performance and mechanical properties of commercially available non-combustible thermal insulation products (e.g. glass wool, rock wool, aerated mortar) was gathered by reviewing scientific literature and publicly available product specification sheets.

[0141] Considering the density range between 70-160 kg / m3, the thermal conductivity of KN composite foam was found to be lower than glass wool and aerated mortar (Figure 1). However, it lies within the scatter band of rock wool and Envirofoam. It is noted that all the insulations demonstrated often quite similar thermal conductivities when the density was around 70 kg / m3.

[0142] The compression strength is an important factor that needs to be considered when evaluating thermal insulation materials. Figure 2 shows the compression strength results for different densities. Considering the density around 100 kg / m3, KN composite foam shows the lower compression strength compared to aerated mortar but higher compression strength than rock wool and Envirofoam. For higher densities, KN composite foam yields significant improvements to compression strength. For example, at a nominal density of 153 kg / m3the compression strength is double (x 1.9) its’ strength at 109 kg / m3(nominal density).

[0143] The thermal efficiency of building floor, wall and ceiling insulation are benchmarked by their thermal resistivity or R-value (equivalent to the inverse of the European U-value). Presented in Figures 3(a)-(c) are the R-values for various commercially available non-combustible thermal insulations for a range of thicknesses. It can be seen that KN composite foam is placed comparable to the glass wool products produced by Pink batts, Earthwool and Bradford (Figure 3a). KN composite also appears comparable to Rockwool (Figure 4b). The thermal resistivity data for KN composite foam, Envirofoam and aerated mortar is shown in Figure 3c for comparable densities. Densities of 100 and 150 kg / m3are respectively identifiable by the open and filled circles.The thermal resistivity of KN composite foam is higher than aerated mortar by 6% for a density of 100 kg / m3and by 9% for a density of 150 kg / m3regardless of the thickness up to 300 mm. Compared to Envirofoam, the thermal resistivity is similar for a density of 150 kg / m3, but 8% lower for a density of 100 kg / m3.

[0144] Figure 1 suggests that the lower density KN composite foam is more effective in thermal insulation compared to glass wool and aerated mortar, but similar to Envirofoam. At a nominal density of 100 kg / m3the compression strength (Figure 2) is second only to aerated mortar which showed the highest compression strength of the noncombustible thermal insulations considered in this comparison. KN composite foam achieved a high compression strength (60 kPa) when the nominal density reached 153 kg / m3, becoming the third highest. Comparison of the thermal resistivity (R-value) of the various thermal insulations revealed KN composite to have comparable thermal insulation performance to Envirofoam and mineral wool, and superior performance to aerated mortar (Figure 3).Example 5 - Fire Performance Assessment of the KN Composite Foam

[0145] The reaction to fire of a KN composite foam was tested in accordance with ASTM 1530.1: 1994(R2016) with variations as shown in Table 2. Before conditioning, the samples had an average density of 342 kg / m3. After conditioning at 23 °C the density of the samples reduced to 180 kg / m3. After further conditioning at 60 °C the density of the samples reduced to 157 kg / m3. The results of the testing are shown in Table 3.Table 2. Test procedure for the reaction to fire test of the KN composite foam.Table 3. Summary of results for the reaction to fire test of KN composite foam.

[0146] After the test, it was observed that the colour of the specimens had changed (Figure 4). The size of the specimens was about 35 mm in height and 30 mm in diameter after the test.

[0147] The KN foam composite was not deemed combustible according to the test criteria for combustibility specified in clause 3.4 of AS 1530.1: 1994 (R2016). A comparison between the performance criteria and the corresponding results determined from testing is presented in Table 4.Table 4. Combustibility performance of the KN composite foam.Example 6 - Fire Performance Assessment of the KN Composite Panel

[0148] The reaction to fire of a KN composite panel was tested in accordance with ASTM 1530.1: 1994(R2016) with variations as shown in Table 5. Before conditioning, the samples has an average density of 1515 kg / m3. After conditioning at 23 °C the densityreduced to 1230 kg / m3. After further conditioning at 60 °C the density reduced to 1105 kg / m3- The results of the tests are shown in Table 6.Table 5. Test procedure for the reaction to fire test of the KN composite panel.Table 6. Summary of results for the reaction to fire test of the KN composite panel.

[0149] After the test, the blue spots that were present in the sample before the tests had changed to khaki (Figure 5).

[0150] The KN composite panel was not deemed combustible according to the test criteria for combustibility specified in clause 3.4 of AS 1530.1: 1994 (R2016). A comparison between the performance criteria and the corresponding results determined from testing is presented in Table 7. Images of the panel sample before and after testing are shown in Figure 5.Table 7. Combustibility performance of the KN composite panel.

[0151] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A curable fire -performance composition comprising: an aluminosilicate; a silicate; an inorganic hydroxide; and optionally, water.

2. A curable fire performance composition consisting of: an aluminosilicate; a silicate; an inorganic hydroxide; optionally, water; and optionally one or more additives selected from the group consisting of strengthening additives, a density modifying additives, viscosity modifying additives, surfactants, and proteins.

3. The curable fire performance composition of claim 1 or claim 2, wherein the ratio of the amount of aluminosilicate to the amount of inorganic hydroxide is between about 1:5 and about 5: 1, between about 1: 1 and about 5: 1, between about 1.2: 1 and about 4.2: 1, between about 1: 1 and about 4: 1, between about 1: 1 and about 3: 1, between about 1.5: 1 and about 2.5: 1, or about 2: 1.

4. The curable fire performance composition (e.g. composite panel) of any one of claims 1 to 3, wherein: the aluminosilicate is present in an amount of between about 20% and about 80% of the total weight of the composition, the silicate is present in an amount of between about 5% and about 50% of the total weight of the composition, the inorganic hydroxide is present in an amount of between about 5% and about 30% of the total weight of the composition, and the water, when present, is present in an amount of between about 10% and about 35% of the total weight of the composition.

5. The curable fire performance composition (e.g. composite foam) of any one of claims 1 to 3, wherein:the aluminosilicate is present in an amount of between about 1% and about 30% of the total weight of the composition, and the silicate is present in an amount of between about 1% and about 20% of the total weight of the composition, and the inorganic hydroxide is present in an amount of between about 2% and about 20% of the total weight of the composition, the water, when present, is present in an amount of between about 3% and about 80% of the total weight of the composition.

6. The curable fire performance composition (e.g. pre-mix) of any one of claims 1 to 3, wherein the aluminosilicate is present in an amount of between about 20% and about 80% by weight of the composition, and the silicate is present in an amount of between about 5% and about 30% by weight of the composition, and the inorganic hydroxide is present in an amount of between about 15% and about 30% by weight of the composition.

7. The curable fire performance composition of any one of claims 1 to 6, wherein the aluminosilicate is a pozzolanic material.

8. The curable fire performance composition of any one of claims 1 to 7, wherein the aluminosilicate is selected from the group consisting of slag, fly ash, metakaolin, red mud, sewage sludge and calcined clay.

9. The curable fire performance composition of any one of claims 1 to 8, wherein the aluminosilicate is a slag, preferably a slag selected from the group consisting of blast furnace slag, ground granulated blast furnace slag, and powdered granulated blast furnace slag.

10. The curable fire performance composition of any one of claims 1 to 9, wherein the silicate is selected from the group consisting of aluminosilicates, alkali alumina- silicates, magnesium silicates, calcium silicates, sodium silicates, and combinations thereof.

11. The curable fire performance composition of any one of claims 1 to 10, wherein the silicate is a sodium silicate, preferably sodium meta silicate.

12. The curable fire performance composition of any one of claims 1 to 11, wherein the sodium silicate is a refined sodium silicate.

13. The curable fire performance composition of any one of claims 1 to 12, wherein the inorganic hydroxide is an alkali metal hydroxide.

14. The curable fire performance composition of any one of claims 1 to 13, wherein the inorganic hydroxide is sodium hydroxide.

15. The curable fire performance composition of any one of claims 1 to 14, further comprising a density modifying additive.

16. The curable fire performance composition of claim 15, wherein the density modifying additive is selected from the group consisting of proteins, hollow microspheres, and combinations thereof.

17. The curable fire performance composition of claim 15 or claim 16, wherein the density modifying additive is a hollow microsphere, preferably a glass hollow microsphere.

18. The curable fire performance composition of any one of claims 15 to 17, wherein the density modifying additive is present in an amount of between about 1% and about 30% of the total weight of the composition.

19. The curable fire performance composition of any one of claims 1 to 18, further comprising a strengthening additive.

20. The curable fire performance composition of claim 19, wherein the strengthening additive is a fibre material, preferably wherein the strengthening additive is selected from the group consisting of polymer fibre, glass fibre, basalt fibre, or carbon fibre.

21. The curable fire performance composition of claim 19 or claim 20, wherein the strengthening additive is basalt fibre.

22. The curable fire performance composition of any one of claims 19 to 21, wherein the strengthening additive is present in an amount between about 1% and about 40% by weight of the total weight of the composition.

23. The curable fire performance composition of any one of claims 1 to 22, further comprising at least one additive selected from the group consisting of: a viscosity modifying additive; a surfactant; and a protein.

24. The curable fire performance composition of any one of claims 1 to 23, wherein the composition does not substantially comprise cement.

25. The curable fire performance composition of any one of claims 1 to 24, further comprising water.

26. The curable fire performance composition of any one of claims 1 to 25, wherein the composition is deemed non-combustible under AS 1530.1-1994 or AS 1530.4- 2005.

27. The curable fire performance composition of any one of claims 1 to 26 in the form of a slurry.

28. The curable fire performance composition of any one of claims 1 to 27 in the form of a foam, optionally a hardened or set foam.

29. A fire-performance composite comprising or consisting of a cured product of the curable fire-performance composition of any one of claims 1 to 28.

30. A fire -performance article comprising the fire-performance composite of claim 29, or the curable fire -performance composition of any one of claims 1 to 28.

31. The fire-performance article of claim 30, in the form of a panel, optionally a foam panel or a cladding panel.

32. The fire-performance article of claim 29 or claim 30, wherein the fire performance composition forms the core of the fire -performance article.

33. A composite panel comprising two outer layers and a core, wherein the core comprises the fire-performance composite of claim 29, or fire-performance composition of any one of claims 1 to 28.

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