RU2157757C2 - Extruded commercial product (versions) and method of its manufacture (versions) - Google Patents

Abstract

FIELD: methods and systems for manufacture of commercial products from hydraulically hardened material containing reinforcing threads, for instance, continuous fibers. SUBSTANCE: method of manufacture of commercial product from water-hardened material includes mixing together of hydraulically hardened binding substance, filling material, substance varying rheological characteristics and water in specific concentrations. In so doing, hydraulically hardened mixture is obtained which posses fluidity in extrusion through spinneret and immediately acquiring stability upon leaving the spinneret. Simultaneously with extrusion of this mixture through spinneret, fibers are continuously laid into mixture. In this case, continuous and simultaneous winding of, at least, one fiber by means of laying device is effected to produce product containing, at least, one wound fiber. Use is made of laying device made for direct introduction and simultaneous winding of one or several fibers into hydraulically hardened mixture with different depth of immersion, angle of winding and concentration of fibers inside product. Extruded hydraulically hardened mixture is hardened with formation of hydraulically hardened matrix for commercial product. Extruded commercial product contains hydraulically hardened mixture including hydraulically hardened binding substance, at least, one filling material and water. Product contains, at least, two fibers included into hydraulically hardened matrix which are continuous and sufficiently flexible. At least, two continuous flexible fibers are laid into hydraulically hardened mixture with their crossed orientation. Versions of extruded commercial product and versions of its manufacture are also offered. EFFECT: provided manufacture of hydraulically hardened products reinforced with continuous fibers featuring high strength and impact elasticity. 69 cl, 33 dwg

Description

1. The technical field to which the invention relates.
The present invention relates to methods and systems for the manufacture of industrial products from hydraulically settable mixtures containing reinforcing threads (e.g., continuous fibers). More specifically, the present invention relates to methods and systems for the extrusion of hydraulically settable mixtures, carried out in order to give them the desired shape of the products, while placing reinforcing fibers in the structural matrix of the extruded products. The composition of hydraulically settable mixtures is calculated using the method of microstructural engineering and provides rheological characteristics that contribute to the high fluidity of the mixtures under pressure and the immediate acquisition of form stability after extrusion, even though the mixture will be in a raw or uncured state at this time . Reinforcing fibers in a hydraulically settable matrix increase tensile, bending, and tensile strength under the influence of internal pressure (in the case of pipes or other hollow products), elastic modulus, elongation and deformation during destruction of extruded products.

2. Applied technology
Hydraulically settable materials, such as materials containing a hydraulically settable binder such as hydraulic cement or gypsum (hereinafter referred to as "hydraulically settable", "hydraulic" or "cement" formulations, materials or mixtures), have been used for millennia to erect, as a rule , large, voluminous structures that are resistant, durable and relatively inexpensive. Hydraulic cement is a hydraulically settable binder based on limestone and clay, and gypsum is a natural mineral. The resources of these materials are practically inexhaustible.

 Hydraulically settable materials are typically formed by mixing a hydraulically settable binder to form a hydraulically settable mixture, upon curing of which concrete, for example, is formed. Typically, a freshly blended hydraulically settable mixture is an almost inviscid suspension, semi-fluid, and amenable to manual mixing and shaping. Due to the liquid state of the mixture, the formation of a hydraulically settable mixture is usually done by pouring the mixture into a mold (formwork), sealing to eliminate large air plugs and subsequent curing.

 Due to the high degree of fluidity required for the ability to process conventional hydraulically settable mixtures, the use of concrete and other hydraulically settable materials is mainly limited to the creation of simple-shaped products, which are usually large, heavy and bulky, in order to maintain the shape of the material in sufficient time to harden requires the application of mechanical forces. Another aspect of traditional hydraulically settable mixtures or suspensions is associated with a practical lack of dimensional stability, which is why the mixture is poured into a free volume to give the products a final shape, limited by externally supported walls or partitions. The problem of low dimensional stability is complicated due to the long duration of setting and curing of most types of concrete. Acquisition of sufficient strength by most cement mixtures to remove formwork without damaging the product requires several days, and to prevent defects in the structural matrix, it is necessary to wet cure for several weeks.

 The use of hydraulically settable materials is also limited due to the strength characteristics of concrete, namely in connection with a high ratio of compressive strength and tensile strength, which, as a rule, is about 10: 1. Nevertheless, the strength limitations of concrete can often be circumvented by casting massive structures of huge sizes. This is possible due to the extremely low cost of most types of concrete. The strength of such massive structures in tension and bending can be increased due to the widespread use of large metal reinforcing rods, called "reinforcement". Similarly, at the "microscopic" level, the inclusion of relatively small cut or interrupted fibers in the hydraulically settable structural matrix can substantially increase, for example, the strength and elongation, as well as the toughness of the cured hydraulically settable products. By thoroughly mixing the fibers inside the crude hydraulically settable mixture, it is possible for the fibers to bond well with the hydraulically settable matrix and to minimize the number of structural defects of the matrix.

 Attempts have already been made to introduce long fibers into the cement structural matrix in the form of mats, cords, wire frame, yarn or threads, but a significant increase in the strength and toughness of the products has not been achieved. One of these methods is “stacking” technology, in which the appropriate source of continuous fibers (such as a mat or cord) is laid in the desired configuration, usually inside the formwork or technological mold, after which the corresponding hydraulically settable mixture is poured into the formwork or mold and compacted to provide impregnation and enveloping of continuous fibers. However, due to the impossibility of completely consolidating the hydraulically settable mixture within the gaps between the continuous fibers, especially when the continuous fibers or filaments are relatively close to each other, the hardened hydraulically settable structure will usually have a structural matrix with a significant amount or volume of undesired voids or defects. In many cases, the complete removal of unwanted voids and the consolidation of the hydraulically settable mixture are not possible even due to the application of pressure or vibration compaction of the hydraulically settable material with a filler in the form of continuous fibers. Usually, the unsatisfactory condition and low strength of cement mixtures filled with continuous fibers by the laying method do not allow using the increase in strength characteristics that should have been achieved by incorporating continuous fibers into the cement mortar.

 In an attempt to improve the placement of continuous filaments in a cement matrix, some researchers have used conventional filament winding methods by which continuous filaments are wrapped around a previously molded raw cement mixture rotated on a mounting mandrel and crashed into the mixture. See F. Strabo et al., “Nye Formgivningsmetoder til Fiberbeton,” Byggeteknik Institut, April 1987 (F. Strabo et al., “A New Method of Forming Concrete with Fiber Filler,” Danish Institute of Technology, April 1987). One of the advantages of this method is the possibility of laying various fibers in a cement material in various concentrations, as well as at different angles relative to the longitudinal axis of pipes or cylinders on which the fibers are wound. Using conventional methods of winding threads, it was possible to carry out spiral (helical) and cross winding of fibers. It can be expected that a change in the concentration and (or) orientation of the continuous fibers will significantly affect the strength, toughness and other required characteristics of the final cured cement product.

 As a rule, winding continuous fibers (filaments) is used to increase the tensile strength of hollow cylinders or pipes under the influence of internal pressure, which can significantly increase the internal pressure that such cylinders or pipes can withstand without damage or destruction. The effect of winding the threads on the strength under internal pressure is increased in the case of winding the threads with crossing or overlapping, at a relatively large angle relative to the longitudinal axis of the cylinder or pipe and at a relatively high concentration in the material in which they are placed.

 Although the method of winding yarns indicated by Strabo et al. Significantly improves the quality of the final cement products, this method proved to be laborious and expensive and was economically inefficient for the large-scale production of such cement materials with reinforcement by winding fibers. In addition, the surface quality of such cemented materials with wound fibers, as a rule, was unsatisfactory due to the effect of cutting through the surface of the fiber and the internal volume of the raw cement material. Effective consolidation of the cement material into which the fibers were embedded often required manual surface smoothing or other labor-intensive operations.

 It is clear that neither the laying method nor the traditional methods of winding the threads will be able to provide a continuous technological process of forming hydraulically set materials with the aim of manufacturing inexpensive mass-produced products. Some researchers have tried to extrude cement materials to ensure the continuous production of cement products such as pipes or rods. See United States Patents N 3857715 to Humphrey (Humphrey) and N 5588443 to Bache et al. (Bake et al.). However, although these patents state that the materials described therein can be extruded using conventional extruders and dies, such extrusion experiments were carried out only in the laboratory and only under experimental conditions. To date, no workable processes have been developed for the continuous extrusion of a cement mixture, with the exception of the extrusion of flat slabs or sheets. See, for example, United States Patents N 5047086 to Hayakawa et al. (Hayakawa et al.), 4,613,627 to Sherman et al. (Sherman et al.) And 4,655,981 to Nielsen et al. (Nielsen et al.). In addition, the materials described in the above patents are not dimensionally stable and therefore suitable only for extrusion of flat plates or thick sheets that rest on a conveyor belt or platform until they harden.

 Due to the compromise between workability (or formability, which allows extrusion) and dimensional stability during horizontal extrusion, carried out by traditional methods, the wall thickness of cement materials in the case of the manufacture of hollow objects (e.g. pipes) should be, as a rule, about 25% of the cavity section, whereas typical objects manufactured by vertical extrusion may have a wall thickness to cavity section ratio reaching approximately 1:16.

 Even after full cure, typical cement materials, including those described in the aforementioned extrusion process patents, have relatively low tensile and flexural strengths as compared to other materials such as paper, metal or plastic. In addition, these patents do not describe methods for continuously reinforcing extrusion cement products by parallel laying or fiber winding. Thus, even these extrudable materials can be used mainly only for the manufacture of large, massive and heavy objects. Therefore, a significant improvement in this field of technology would be the possibility of manufacturing a variety of products of complex shape or with precise tolerances from hydraulically settable materials, which, in particular, is due to the extremely low cost of hydraulically settable materials in comparison with most other materials. An even more significant achievement in this field of technology would be the possibility of manufacturing hydraulically settable products reinforced with continuous fibers, which would increase their strength and toughness, so that such products could replace products from conventional materials such as plastic, metal, wood or clay which are currently used for the manufacture of products such as, for example, pipes, window frames, bars, moldings, rods, etc.

 Due to the recent increase in understanding of the harm caused to the environment through the massive use of plastic, metal and wood for the manufacture of a huge number of durable and non-durable products, there is an urgent need to find environmentally friendly replacement materials suitable for replacing such products . Hydraulically settable materials could be one of the environmentally friendly substitutes. Despite the perceptible pressure and the long-recognized need, until now there was practically no technology for the economical and efficient production of cement materials that could replace plastic, metal or wood in the manufacture of a wide variety of products.

 Hydraulically settable materials are environmentally friendly, since they mainly consist of aggregates in the form of natural geological materials, such as sand and clay, which are bonded together by the reaction products of a hydraulically settable binder and water and which are essentially “stone-like” with structural and, in features, chemical point of view. Hydraulically settable materials have basically the same chemical and structural composition as the earth into which the waste of such materials can ultimately be disposed of.

 In addition, plastics, metal and wood are much more expensive than typical hydraulically settable materials (including cementitious materials). Since no rational economic organization would ignore the economic effect that would certainly have been obtained by replacing plastic, metal, or wood materials with significantly cheaper hydraulically settable materials, the absence of such products can only be explained by the apparent lack of technology that would allow such a replacement.

 Given the above, an improvement of the current level of this branch of technology would be compositions, methods and devices that would provide the possibility of simultaneous laying of continuous fibers during the extrusion of hydraulically set materials for the manufacture of products and shaped profiles, which was previously impossible due to the strength and formability the limitations inherent in currently known hydraulically settable formulations.

 Another achievement in the art would be compositions, methods and devices for extruding and stacking continuous fibers in hydraulically settable products in which the ratio of tensile strength and compressive strength is increased compared to conventional hydraulically settable materials.

 A significant achievement in this field of technology would be compositions, methods and devices that would allow the continuous extrusion of a hydraulically settable mixture with the simultaneous laying of continuous fibers so that the extruded products or profiles immediately acquire shape stability (i.e., sufficient strength to maintain their shape without external support) in a wet state after exiting the extrusion die.

 Another improvement in this technical field would be the possibility of using such compositions, methods and devices for continuous laying in an extrudable hydraulically settable mixture of long fibers, where the fibers are used in various desired concentrations.

 In addition, a significant achievement in the art would be the possibility of laying continuous fibers with a different orientation or at different angles relative to the longitudinal axis of the extrudable product in a hydraulically settable mixture.

 Another significant improvement in this technical field would be the possibility of using such compositions, methods and devices for the extrusion of form-resistant pipes and cylinders with significantly increased tensile strength under the influence of external or internal pressure.

 Another significant achievement in this field of technology would be the possibility of using such compositions, methods and devices for effective consolidation or compaction of a hydraulically settable mixture around and between continuously laid fibers, which will minimize the number and volume of internal voids or defects and, therefore, thereby, obtain a hardened hydraulically settable structural matrix, which will have a substantially uniform structure and uniform high strength.

 Another improvement in this technical field would be the possibility of using such compositions, methods and devices for the extrusion of hydraulically settable products with continuously laid fibers, which would have a significantly higher surface quality with a significant reduction in the concentration of surface defects in comparison with the known methods of manufacturing cemented materials with wound fibers.

 Another achievement in the art would be the possibility of using such compositions, methods and devices to produce a variety of thin-walled hydraulically settable products, including products with very tight tolerances or exact dimensions.

 A significant achievement in this field of technology would be compositions, methods and devices that could be used for the extrusion of hydraulically settable products with continuously laid fibers, which could replace products currently made from traditional materials, such as plastic, clay, metal or wood.

 Another achievement in the art would be to give hydraulically settable compounds rheological characteristics and ductility similar to clay characteristics, which would allow extrusion of such compositions using extrusion devices designed for clay.

 From the point of view of practice, a significant achievement would be the possibility of using such compositions, methods and devices for the continuous production of various hydraulically settable products at such a cost of mass production (i.e., manufacturing in large volumes or quantities) that is comparable to the cost of manufacturing such products from plastic, clay, metal or wood, or even be below this cost.

 Such compositions, methods and devices are disclosed herein and are the subject of this patent application.

SUMMARY OF THE INVENTION
The present invention relates to new hydraulically settable compositions, methods and devices used for the extrusion of hydraulically settable compositions while laying continuous fibers to form a variety of products. Such fibers can be laid longitudinally and / or curled at an angle to the longitudinal axis. Preferred hydraulically settable compositions can be described as multicomponent multidimensional fiber reinforced microcomposites. By carefully considering the inclusion of a wide variety of materials (including hydraulically settable binders, inorganic fillers, rheology modifiers and fibers) that give the product various, but synergistic (i.e., mutually reinforcing) properties, it is possible to create a unique class of microcomposites with outstanding characteristics strength, viscosity, environmental neutrality, manufacturability for mass production and low cost.

 Such compositions can be used for the extrusion of a variety of shaped profiles, from the simplest and ending with products with tight tolerances and thin walls. Due to the continuous nature of both technological processes - extrusion and fiber laying - such products can be manufactured with high economic efficiency and low cost. In addition, the hydraulically settable materials of the present invention are environmentally neutral and consist of materials that practically have the same properties and characteristics that are inherent to the earth.

 Using the method of microstructural engineering, a hydraulically settable mixture can give the required rheological characteristics (including workability, yield strength, viscosity and wet strength) and final strength in the cured state. In addition, characteristics such as high packing density of particles, impact strength, tensile strength and elongation at break can be imparted to the mixture in advance. Moreover, by laying fibers with the required characteristics of strength and flexibility, using an almost infinite number of combinations of different orientations and concentrations, it is possible to provide continuous production of reinforced products with even higher rates of strength, durability, flexibility and toughness.

 A common problem inherent in typical hydraulically settable mixtures, namely the compromise between good workability and high wet strength, is solved by creating a hydraulically settable mixture with a relatively high yield strength and seemingly low viscosity, manifested by high pressure and shear stresses during extrusion. Due to this, the present invention provides good workability (i.e., high ductility) during extrusion with the immediate acquisition of form stability after completion of this process.

 Formability during extrusion and high wet strength (i.e., form stability) of the hydraulically settable mixtures of the present invention are ensured by combining previously considered incompatible methods for optimizing particle packing and creating a water deficit, which makes it possible to create a material with relatively high stiffness and high shear, but possessing good workability under the action of high pressure and high shear stresses characteristic of the extrusion process. By choosing aggregates with various carefully selected parameters, such as particle diameters, particle size distribution ("hGH") and packing density, it is possible to reduce the intermediate space between particles, since the space between large particles is filled with small particles, and the space between these small particles particles, in turn, is filled with even smaller particles. In this way, particle packing densities in the range of about 65% to as high as about 99% can be achieved. This means that approximately 65% to 99% of solid materials and only about 35% to 1% of the intergranular space, or voids, will be included in the volume of the dry hydraulically settable mixture.

 By carefully dispensing the water added to the hydraulically settable mixture, it is possible to create a mixture with a precisely selected degree of "water scarcity". (As described in more detail below, it should be understood that water is added to a hydraulically settable mixture for two main reasons: (1) for a chemical reaction (“hydration”) with a hydraulically settable binder, and (2) for filling voids between particles to reduce friction between particles and their lubrication, which is necessary to give the mixture adequate plasticity and cohesion.If the amount of water is insufficient, then the friction between the particles increases, which leads to an increase in the stiffness of the material. Depending on the concentration water or other additives (such as dispersants that can be introduced to lubricate or disperse the particles), a specialist in the industry can carefully control the rheological characteristics to ensure the required level of workability (ductility) under pressure.

 It should be understood that to fill the intermediate voids in a mixture with an increased packing density of particles, much less water will be required. Therefore, it is preferable even before adding water to determine the amount of water required to provide the required level of water scarcity, and this amount of water will mainly depend on the efficiency of the packaging of particles and the expected degree of compression during extrusion.

 The corresponding hydraulically settable mixture obtained is placed in an extruder and subjected to pressure. The resulting compression contributes to an increase in packing density due to the compression of particles against each other, which, in turn, leads to a reduction in the volume of intermediate voids between the individual particles of the mixture. In this case, the "effective" level of water scarcity decreases, which leads to an increase in the amount of water used to lubricate the particles (as well as to lubricate the hydraulically settable mixture during its movement through the extruder die), as a result of which the hydraulically settable mixture acquires increased formability and the ability to adrift. Moreover, compression of the mixture during extrusion also results in the formation of a thin film of water between the mixture and the extruder die, which serves to lubricate the interface between the mixture and the die. In addition, the extruder die can be heated to create the effect of a “steam pad” or barrier between the extruded hydraulically settable mixture and the extruder die, which reduces friction and facilitates extrusion. After that, the formed internal capillaries, or menisci arising from the compression of the mixture, create internal adhesion forces, providing an increase in the form stability of the mixture after extrusion.

 The high level of formability and fluidity of the mixture under pressure allows the extrusion of the mixture through a die to give the mixture the desired shape of the product or shaped profile. Enabling the extrusion of a hydraulically settable mixture and high dimensional stability is carried out in one of two ways. First, since the behavior of most hydraulically settable mixtures of the present invention approximately corresponds to the behavior of a Bingham fluid or a pseudoplastic body, the viscosity of the mixture will decrease after exceeding the critical shear stress applied as pressure. In other words, the hydraulically settable mixtures of the present invention typically experience “shear thinning” with increasing pressure (and hence shear stresses), for example, in an extruder designed for high pressure. Thus, by applying high pressure (and creating an appropriate shear stress), it is possible to extrude most hydraulically set mixtures of the present invention.

 Instead of applying high pressure or in addition to this, it may also be preferable to develop a composition of a hydraulically settable mixture that provides the lowest possible ratio of viscosity to yield strength. As the viscosity decreases, the stress decreases beyond the yield strength of the material, necessary to ensure the flow of the mixture. This strategy is especially useful when extrusion is desired to be carried out under reduced pressure.

 Upon completion of the extrusion, the mixture is no longer exposed to the compressive and shear forces acting in the extruder, as a result of which the mixture acquires increased stiffness, toughness, cohesion, shape stability and wet strength. The value of the crude strength provided by the compositions, methods and devices of the present invention is much higher than the strength achieved using known cement compositions, methods and devices.

 In addition to the hydraulically settable binder, water, and fillers, the hydraulically settable compositions of the present invention may also include other components, such as rheological modification agents, dispersants, and short fibers. Reagents for modifying rheological characteristics can be added to increase the yield strength, adhesion (cohesion) and plasticity of the hydraulically settable mixture, while dispersants can be added to maintain the flow properties of the mixture while reducing the concentration of water. Fibers are usually added to increase the toughness of the final cured product, as well as its tensile, bending, and sometimes even compressive strengths.

 More specifically, reagents for modifying rheological characteristics increase "pseudoplasticity" in the sense of maintaining the shape of the mixture after compression or extrusion. Suitable reagents for modifying rheological characteristics include various materials based on cellulose, starch and protein, which can be ionic and non-ionic and which act by gelling (thickening) water and binding individual particles of a hydraulically settable binder and other particles in a hydraulically settable mixture. By increasing the "pseudo-plasticity" of the consistency of the hydraulically settable mixture, the reagent for modifying the rheological characteristics also contributes to the extrusion of articles with high dimensional stability. (You can also add gypsum hemihydrate, which helps to increase form stability through a quick reaction with water, which helps to quickly reduce the volume of capillary water present in a hydraulically settable mixture. Thus, in some cases, gypsum hemihydrate can act as a reagent to modify rheological characteristics.)

 Dispersants, in contrast, reduce the viscosity and yield strength of the mixture due to the dispersion of individual particles of a hydraulically settable binder. This allows you to reduce the concentration of water while maintaining sufficient workability, which makes it possible to increase the degree of scarcity of water. Suitable dispersants include any materials that can be adsorbed by the surface of the particles of a hydraulically settable binder and provide dispersion of particles, which is usually accomplished by creating a negative electric charge on the surface of the particles or in an adjacent double colloidal layer. Excipients such as kaolin, mica, calcium carbonate or bentonite are also substantially dispersed when using a dispersant.

 However, in cases where a dispersant and a reagent are used simultaneously to modify the rheological characteristics, it is usually preferable to first introduce a dispersant and then a reagent to modify the rheological characteristics, which will ensure a favorable effect of both components. Otherwise, if the reagent for modifying the rheological characteristics is adsorbed by the binder particles, it forms a protective colloidal layer on the surface that prevents adsorption of the dispersant by particles, which will reduce the dispersion effect of the dispersant inside the hydraulically settable mixture.

 In addition to adding aggregates with different diameters, shapes, sizes and characteristics (i.e. specific gravity, bulk density and morphology), it may be desirable to add aggregates with different strength and thermal insulation properties. In this way, it is possible to optimize the hydraulically settable mixture both from the point of view of the required rheology or the flow characteristics used in the extrusion process, and from the point of view of the final characteristics of the cured material.

 And finally, the main feature of the novelty of the present invention is to create the possibility of introducing filaments, or continuous fibers, into the structural matrix of the extrudable product, which is carried out during the extrusion process. The introduction of continuous fibers during the extrusion process involves laying the fibers in a mixture that envelops the fibers and draws them into a hydraulically settable mixture in the direction in which the extrusion is carried out, i.e. extrusion of the mixture. As a result of the application of internal pressure to the mixture during extrusion, the mixture is consolidated or compacted, which minimizes the amount of internal voids or defects inside the mixture and maximizes the contact area between the fibers and the hydraulically settable mixture. An increase in the contact area between the fibers and the matrix makes it possible to more reliably fix the fibers inside the hydraulically settable structural matrix.

Various embodiments of a device for continuously stacking fibers in an extrudable hydraulically settable mixture allow fibers to be placed in various configurations or orientations. These configurations include parallel laying, spiral laying, cross-laying, or a combination thereof. In a “parallel configuration”, the fibers are laid approximately parallel to the longitudinal axis or the extrusion direction of the hydraulically settable product. In contrast, with the “spiral configuration” and the “cross configuration” (which is a variation of the spiral configuration), the fibers are laid at an angle α to the longitudinal axis, usually from 5 ^o (minimum) to 90 ^o (maximum). This angle may be referred to below as “offset angle”, “winding angle” or “spiral angle”. (Depending on the direction of rotation of the device for laying the fibers, i.e. clockwise or counterclockwise, the angle α can be positive or negative, but its absolute value will not exceed 90 ^o , since the angle 91 ^{o is} equivalent to the angle - 89 ^o ).

By varying the concentration and (or) the angle of orientation of the fibers placed in the extrudable hydraulically settable products of the present invention, it is possible to obtain various characteristics of strength, elongation and toughness. Fibers stacked at a small angle of winding, as a rule, define an elliptical section of the products in the form of a pipe or cylinder into which they are stacked. As the angle of winding increases to 90 ^{o the} eccentricity of the ellipse formed by the winded fibers decreases. When the winding angle is 90 ^o , the cross section of the product, determined by the fibers, will take the form of a circle. If we assume that the extrudable product is a pipe, cylinder or other product with approximately circular cross-section, then such a product will have a radius approximately perpendicular to the longitudinal axis. In order to determine the direction and magnitude of the strength characteristics imparted by the fibers, it is advisable to determine the strength characteristics imparted by the fibers using vectors characterizing the strength in the radial and axial directions, respectively. If the angle of displacement of the fibers exceeds 0 ^o , but does not reach 90 ^o , then the fibers will provide both axial and radial vector components. It can be expected that with a fiber winding angle not exceeding 45 ^° , the axial strength vector will typically exceed the radial strength vector. Similarly, it can be expected that when the angle of winding of the fibers exceeds 45 ^o , the vector of radial strength, as a rule, will exceed the axial strength vector.

 As a rule, fibers oriented mostly in the longitudinal direction and providing a larger axial strength vector will increase the tensile strength of the hydraulically settable product in axial, i.e. longitudinal direction. Conversely, fibers with a large angle of displacement relative to the longitudinal axis, i.e. fibers providing a larger radial strength vector will increase the tensile strength of the hydraulically settable product around the circumference (in the case of pipes or other hollow structures, this indicator is called crush strength (crushing) or rupture under the influence of internal pressure). To give strength in both directions, a combination of fibers with large and small angles of displacement can be used.

 The device is equipped with means for the continuous laying of fibers in an extrudable hydraulically settable mixture, which are in direct communication with the fiber stacking chamber, which is the inner chamber of the extruder. The device is also equipped with means for storing and continuously feeding fibers to at least one of the stacking means.

 Laying means place the fibers on or below the surface of the hydraulically settable structural matrix, after which the hydraulically settable mixture entrains the fibers as the mixture moves. The styling means can be a rotary device rotating clockwise or counterclockwise around the fiber stacking chamber by means of a mechanism for rotating the styling means to provide spiral winding of the fibers inside the product along the same axis along which the extrusion is carried out. Laying means can also be a stationary device that maintains a fixed position and stacks the fibers parallel to the axis. The use of at least two styling devices at different speeds or orientations will make it possible to obtain a product equipped with fibers that are laid with different angles of displacement relative to the longitudinal axis.

 Any laying means includes a mechanism for feeding at least one fiber to the laying means, a yarn guide device for guiding the incoming fiber through the laying means, and a device for introducing the fiber into the fiber laying chamber. The input device may be of any shape that allows fibers to be placed on or under the surface of a hydraulically settable structural matrix, and may have various cross-sectional shapes. An example of an input device is a hollow needle, or a device with a pointed or scooped tip protruding from a yarn guide device into a fiber-laying chamber.

 Means for storing and continuously feeding fibers to at least one of the stacking means include a fiber dispenser, such as a bobbin. In addition, means for storing and continuously supplying fibers to at least one of the stacking means include at least one annular feeder serving as a support for at least one fiber dispenser (distributor). Means for storing and continuously feeding fibers can rotate together with rotational styling means, or they can remain stationary when using stationary styling means. The fiber dispenser can also be equipped with tensioning devices for tensioning the fibers.

 The laying depth of the fibers inside the hydraulically settable structural matrix can be changed by changing the position of the laying means. The laying depth can also be changed due to the selective adjustment of the fiber tension provided by the tensioning devices. As a rule, an increase in tension leads to deepening of the fibers. In addition, the extrusion pressure and rheological characteristics of the mixture also to some extent affect the nature of the laying of the fibers.

The angle of winding of the fibers α depends both on the translational speed of the extrusion ("V _c "), and on the peripheral speed ("V _r ") styling. In fact, the tangent of the angle α is proportional to the ratio of the peripheral speed to the translational extrusion speed (V _r / V _c ). Therefore, ceteris paribus, the higher the extrusion rate, the smaller the angle of winding of the fibers. Conversely, the higher the peripheral speed of the styling means, the greater the angle of winding of the fibers.

 The concentration of fibers inside the hydraulically settable matrix of the extruded product is directly proportional to both the number of fibers and their average winding angle α. As the number of fibers and their winding angle α increase, the fiber concentration increases. The greater the concentration, the less space remains between the individual turns of fibers. This allows for a more significant and uniform effect of the fibers on the hydraulically settable matrix of the extrudable product. Typically, fibers of small diameter, which are more closely adjacent to each other, provide imparting more uniform characteristics, for example, strength, flexibility and toughness, than in the case of fibers of large diameter.

 And finally, depending on their chemical composition, the fibers themselves can have significantly changing characteristics of tensile and shear strength, as well as flexibility and elongation. These characteristics also depend on the diameter of the fibers, as well as on whether they consist of individual threads, or of groups of interwoven or otherwise connected threads forming a single fiber.

 Using the above compositions, methods and devices, it is possible to extrude a variety of products of various shapes, equipped with continuous fibers distributed inside a hydraulically settable product matrix. Such extruded products, as a rule, may include square, rectangular, cylindrical or elliptical rods or beams, plates, I-beams, bars with a section of two by four inches, simple multi-cell structures, pipes, hollow cylinders or other hollow structures, window frames, bricks or roofing tiles. Such products have improved performance by stacking continuous fibers within a substantially consolidated and compacted hydraulically settable mixture, while ensuring tight tolerances if required.

 The characteristics of such products are not inferior to the characteristics of products made of other materials, such as plastic, wood, clay or metal, or even surpass the characteristics of these materials. However, the advantage of hydraulically settable materials is the fact that they are usually much cheaper than the other materials mentioned. In addition, hydraulically settable products made in accordance with the present invention, as a rule, have increased environmental neutrality in comparison with traditional materials that are currently used in industry.

Thus, according to aspects of the present invention, there is disclosed a method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, a filler material, a rheological agent, and water in relative concentrations to produce a hydraulically settable mixture having flowability upon extrusion under pressure through the die and immediately gaining stability after exiting the die; hydraulic extrusion a curable mixture under pressure through a die with simultaneous continuous laying of fibers in the specified mixture and curing of the extruded hydraulically settable mixture to form a hydraulically settable matrix for an industrial product, and when laying the fibers in a hydraulically settable mixture, continuous and simultaneous winding using at least one fiber to obtain products containing at least one wound fiber, and using a styling tool, made Goes to directly input and simultaneous winding of one or a number of filaments within the hydraulically settable mixture with varying depth, the winding angle and the concentration of fibers within the product;
A method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, aggregate material and water in relative concentrations to obtain a hydraulically settable mixture having fluidity during extrusion under pressure through a die and immediately gaining form stability after exiting the die, and hydrically-curable extrusion the mixture under pressure through a die having a longitudinal axis and an inner part through which the mixture passes during extrusion with the formation of an extruded product, the continuous laying of fibers in the specified mixture when it is extruded through a die, and the curing of the extruded hydraulically settable mixture to form a hydraulically settable matrix for an industrial product, and when laying the fibers in a hydraulically settable mixture, continuous and simultaneous winding with a means of laying at least one fiber to obtain an article comprising at least one fiber, and eyuschee winding angle of at least 5 ^o relative to the longitudinal axis, the use stacking means adapted to direct the input and simultaneously winding the at least one fiber wound during input with a different winding angle to at least about 5 ^o relatively the longitudinal axis, with different depths and fiber concentrations within the hydraulically settable mixture;
A method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, a filler material, a rheological material, and water in relative concentrations to produce a hydraulically settable mixture that is fluid when extruded under pressure through a die and immediately becomes mold-resistant after exit from the die, extrusion of a hydraulically settable mixture under pressure through a die having a longitudinal the axis and the inside through which the mixture passes during extrusion to form an extruded product, the fibers are continuously laid in the specified mixture when it is extruded through a die, and the extruded hydraulically settable mixture is cured to form a hydraulically settable matrix for the industrial product, and during laying fibers in a hydraulically settable mixture carry out continuous and simultaneous winding using means of laying at least one fiber to obtain I products, comprising at least one fiber and the winding angle of at least 5 ^o relative to the longitudinal axis, the use stacking means adapted to direct the input and simultaneously winding the at least one fiber wound in the input time with a different a winding angle of at least about 5 ^° relative to the longitudinal axis, with different depths and fiber concentrations within the hydraulically settable mixture;
extruded industrial product containing a hardened hydraulically settable matrix formed from a hydraulically settable mixture comprising a hydraulically settable binder, at least one filler material and water, and immediately acquires shape stability after leaving the die, and at least two fibers included in hydraulically settable matrix and made continuous and flexible enough to fit them in a hydraulically settable mixture when it is subjected to pressure-induced extrusion through a die, and at least two continuous flexible fibers are laid in a hydraulically settable mixture in a cross orientation relative to the longitudinal axis of the product;
an extruded industrial product containing an extruded hydraulically settable hardened mixture comprising products of mixing a hydraulically settable binder, a filler material, a rheological agent, and water, the product having a longitudinal axis and at least two continuous flexible fibers introduced during the extrusion of a hydraulically settable mixture under pressure through a die, and at least two continuous flexible fibers are wound at an angle, at least 5 ^o relative to the longitudinal axis, and at least two continuous flexible fibers are located crosswise;
an extrudable industrial product containing an extruded hydraulically settable solidified mixture comprising products of mixing a hydraulically settable binder, a filler material, a rheological agent, and water, the product containing at least two flexible fibers laid with extruding the mixture under pressure through a die, the product having a hollow core, and at least two flexible fibers have a cross orientation and form an angle at least 10 ^o .

Brief Description of the Drawings
To state the methods for providing the above and other advantages of the invention, a more detailed description of the invention is provided below.

 In FIG. 1, a greatly enlarged front view shows a cross section of a hydraulically settable mixture filled with particles with a relative high natural packing density of 70%.

 In FIG. 2, a greatly enlarged front view shows a cross section of the mixture of FIG. 1, and also shows the corresponding graph, which shows the numerical values of the volume occupied by the particles and the volume of intermediate voids between the particles.

 In FIG. 3, a greatly enlarged front view shows a cross section of the mixture of FIG. 1, in which water is added in a volume equal to the volume of intermediate voids, and also a corresponding graph is shown, which shows the numerical values of the volume occupied by the particles and the volume occupied by water between the particles.

 In FIG. 4, a greatly enlarged front view shows a cross-section of the mixture of FIG. 1, to which water is added in a volume less than the volume of intermediate voids to form a water-deficient mixture; and a corresponding graph is given, which shows the numerical values of the volume occupied by the particles, the volume occupied by water between the particles, and the volume of the remaining intermediate voids between the particles.

 In FIG. 5, a greatly enlarged front view shows a cross-section of the mixture of FIG. 4, to which a compressive force (e.g. pressure) is applied, sufficient to compress the particles; and a corresponding graph is given, which shows the numerical values of the volume occupied by the particles, the volume occupied by water between the particles, and the reduced volume of the remaining intermediate voids between the particles.

 In FIG. 6 shows a cross section of a screw extruder.

 In FIG. 7 shows a cross section of a piston extruder.

 In FIG. Figure 8 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it can be seen that the mixture is extruded in the direction of the fibers.

 In FIG. 9 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it can be seen that the mixture envelops fibers laid in a spiral configuration as the core is formed.

 In FIG. 10 shows a cross section along the transverse axis (along line 10) of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how the fibers are laid by means of laying with a scooped end.

 In FIG. 11 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how the mixture envelops fibers laid in a parallel configuration using stacking means with a scooped end.

 In FIG. 12 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how the mixture envelops fibers laid in parallel configuration using layered ends.

 In FIG. 13 shows a section along the transverse axis (along line 13) of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it can be seen how the fibers are laid by means of laying with a pointed end.

 In FIG. 14 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how the mixture envelops fibers laid in parallel configuration using hollow-needle laying means.

 In FIG. Figure 15 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how the fibers are cross-laid using two sets of rotary laying means.

 In FIG. 16 shows a cross-section along the axis of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture, where it is seen how fibers are laid in parallel using a set of stationary laying means and cross-laying of fibers using two sets of rotary laying means.

 In FIG. 17 shows a general view of a cut-out device for showing a double-tee-shaped fiber stacking chamber, where it is seen how a hydraulically settable double tee is molded with fibers laid parallel to its length.

 In FIG. Figure 18 shows a general view of devices for forming a hydraulically set sheet with fibers laid parallel to the length of the sheet.

 In FIG. 19 is a perspective view of an apparatus with a cutout for showing a fiber stacking chamber having a circular cross section in length and a rectangular cross section at the output end, where it is seen how a hydraulically set rectangular product is formed with rectangular fibers laid in a spiral configuration along the longitudinal axis of the product, and fibers laid in a parallel configuration in the corners and around the perimeter of the product.

 In FIG. 20 shows a general view of a cut-out device for showing a fiber stacking chamber having a circular cross-section, gradually turning toward the end of the chamber into a rectangular cross-section at the output end, as well as a mandrel placed in the stacking chamber having a similar cross-section, varying from round to rectangular, where you can see how the molding of a hydraulically set tubular product of a hollow rectangular cross-section is carried out with fibers stacked in a spiral and parallel configuration relative to the longitudinal axis of the product Leah.

 In FIG. 21 shows a general view of a cut-out device for showing a fiber stacking chamber equipped with several mandrels, where it can be seen how hydraulically set brick is molded with fibers stacked in a parallel configuration along the length of the brick.

 In FIG. 22 shows a general view of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture.

 In FIG. 23 is a side view of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture.

 In FIG. 24 shows a section through a line 24 of a device for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture.

 In FIG. 25 shows a general view of a device (with spatial separation of parts) for laying fibers in a hydraulically settable mixture while extruding a hydraulically settable mixture.

 In FIG. Figure 26 shows a general view of a device for forming a hydraulically settable pipe with parallel fibers laid along the length of the pipe, stacked using a set of stationary laying tools placed in a rotational yarn guide carriage, shown in cross-section, the fibers being fed from bobbins located on a fixed ring feeder.

 In FIG. Figure 27 shows a general view of a device for forming a hydraulically settable pipe with spiral fibers extending along the length of the pipe stacked using a set of rotational stacking tools placed in a rotational yarn guide carriage, shown in section, the fibers being fed from bobbins located on a rotary ring feeder.

 In FIG. Figure 28 shows a general view of a device for forming a hydraulically settable pipe with cross fibers extending along the length of the pipe stacked using two sets of rotational stacking tools, one of which is placed in a rotational yarn guide carriage, shown in section, and the fibers are fed from bobbins located on the rotational ring feeder.

 In FIG. Figure 29 shows a general view of a device for forming a hydraulically settable pipe with parallel and cross fibers extending along the length of the pipe, stacked using a set of stationary laying tools and two sets of rotational laying tools, one of which is placed in a sectional rotation yarn guide carriage, served from bobbins located on a rotary ring feeder.

 In FIG. 30 is a graph showing the dependence of tensile strength under the influence of internal pressure on the percentage concentration of spirally wound fibers in a hydraulically settable product made by known methods.

 In FIG. 31 is a graph showing the dependence of tensile strength under the influence of internal pressure on the angle of winding of spirally wound fibers in a hydraulically settable product made by known methods.

 In FIG. 32 is a graph showing the dependence of the elastic modulus on the percentage concentration of spirally wound fibers in a hydraulically settable product made by known methods.

 In FIG. 33 is a graph showing the dependence of the modulus of elasticity on the angle of winding of spirally wound fibers in a hydraulically settable product made by known methods.

Detailed Description of Preferred Embodiments
The present invention relates to new compositions, methods and devices for the continuous laying of fibers in a hydraulically settable mixture during its extrusion, carried out in order to obtain the desired product. Continuous fibers increase tensile, bending, crushing (crushing) strengths, as well as impact strength, flexibility and elongation of hydraulically settable products. It is possible to mold a variety of products, including products with thin walls, a complex profile and (or) with very tight tolerances. In addition, using the compositions, methods, and devices of the present invention, relatively large and thick-walled objects, such as two-by-four-inch bars or other structural elements, can be efficiently extruded and fiber reinforced. Such extruded products acquire shape stability immediately (or within a few seconds) after extrusion.

 New hydraulically settable compositions can be described as multicomponent multidimensional fiber reinforced micro composites. Due to the carefully thought-out inclusion of a variety of materials (including inorganic materials and fibers) that give the product various, but synergistically related (i.e. mutually reinforcing) properties, it is possible to create a unique class of microcomposites with outstanding characteristics of strength, viscosity, environmental neutrality, processability for mass production and low cost.

 The term "multicomponent" indicates the fact that the inorganic filler materials used to make the sheets and hinges of the present invention typically include at least three chemically or physically different materials or phases, such as fibers, filaments (continuous fibers), inorganic filler materials, organic filler materials, organic polymeric binders, hydraulically settable materials, organic reagents for changing rheological characteristics, dispersants, and other liquids. The materials of each of these broad categories give the final product extrusion (as well as the mixture used to form the product) one or more special properties. Within the framework of these broad categories, various components (such as two or more kinds of particles of inorganic aggregate or fiber material) that can give extrusion products different, mutually complementary properties, can be further included. This allows you to set the specific desired properties of the products in combination with the extrusion process.

 The term "multidimensional" refers to the fact that the compositions and materials used in the present invention are measured at various levels or on different scale scales. For example, in the hydraulically settable materials of the present invention, macrocomponent compositions with an approximate particle size of 0.01 mm to 10 mm, microcomponent compositions with approximate particle sizes in the range of 10 nm to 10 μm, and a submicron component are typically used. Although these levels may not be fractional, they are usually very similar to each other and are homogeneous and homogeneous within each category.

 The term “fiber reinforcement” does not require explanation, although it can equally be attributed to the reinforcing effect of both fibers and threads (or continuous fibers). The structural matrix of the hydraulically settable materials used in the present invention is formed by the bond or interaction between the hydraulically settable binder, inorganic aggregate, rheology modification reagent, fibers and filaments. Fibers and threads act primarily as a reinforcing component, giving the material ductility, tensile strength, bending and tearing under the action of internal or external pressure, flexibility and elongation.

 And finally, the term “microcomposite” refers to the fact that hydraulically settable materials are not just a composition or a mixture, but a given matrix with specific discrete materials that, at the micro level, have different sizes, shapes and chemical compositions. These materials are quite well connected and interact with each other, so that the specific characteristics of each of them are fully manifested in the final composite material (for example, the tensile strength of the matrix is directly proportional to the tensile strength of the fiber or filamentous component; the tensile strength of hollow products directly or indirectly proportional to strength, diameter, laying angle and concentration of long fibers, etc.).

 Given these definitions and principles, it is understood that materials including a hydraulically settable binder, inorganic aggregates, water (optionally) fibers (both organic and inorganic) and (optionally) a reagent to modify rheological characteristics can be combined and used to form various products. Such products can have various characteristics of strength, toughness and density, and can also be manufactured with tight tolerances. This allows continuous extrusion and winding of continuous fibers (i.e. mass production) to produce a variety of products that are currently made, for example, from plastic, metal, wood or clay.

 As described in more detail below, the main parameters of the hydraulically settable mixtures of the present invention include: (1) particle packing density, (2) concentration of a hydraulically settable binder (usually hydraulic cement), (3) water concentration, (4) extrusion pressure, ( 5) rheological characteristics (including yield strength and wet strength), and (6) the strength of the final cured product (including compressive and tensile strength).

1. General description
A. General description of the extrusion process
Hydraulically settable products, including cement materials, and methods of their use have been known for millennia. Various and numerous cement and hydraulically settable products were made from these materials, but they were all large and bulky. In particular, cement objects must be of considerable size and mass in order to provide the required strength and other performance properties. Typical cementitious materials must also set and cure for a relatively long time before they can be freed from the mold. The formability and / or extrusion ability of most hydraulically settable mixtures is usually limited by the trade-off between workability and form stability. When one parameter improves, the second parameter, as a rule, worsens, which leaves only a small range of permissible rheological characteristics.

 This product allows to solve this problem of the compromise between extrusion ability and form stability due to the creation of a highly plastic and cohesive hydraulically settable mixture, which acquires form stability immediately or shortly after extrusion. The term “plastic” refers to a hydraulically settable mixture which has the property of workability, flows under pressure and has sufficient cohesive strength to ensure its shape stability in the wet state (wet strength, i.e., the acquisition of shape stability immediately or within a few seconds).

 The unique characteristics of hydraulically settable mixtures prepared in accordance with the present invention are ensured by careful control of the rheological characteristics, preferably carried out by optimizing the packing density of the particles, as described in more detail below, in combination with providing a water shortage. Water deficiency provides a relatively rigid or highly viscous hydraulically settable mixture, since the available water is not enough to fill all the gaps between the particles and to completely lubricate all the particles. In cases where the initial concentration of water is especially low, the hydraulically settable mixture may consist of dry-looking grains that are not interconnected and do not represent a single mass.

 However, by subjecting the water-deficient mixture to increased mechanical pressure in a screw or piston extruder, and also placing the mixture under vacuum to remove almost all air from the intermediate voids, it is possible to compress the hydraulically settable particles with each other, thereby increasing their packing density. This, in turn, ensures a reduction in the effective water deficit, as a result of which the water more fully fills the gaps between the more densely packed particles. The apparent increase in the concentration of water, which can fill the gaps between the particles, allows to improve the lubrication of particles, reduce friction between particles and increase the fluidity of the mixture due to a temporary decrease in yield strength. In addition, the viscosity of the water-deficient mixture can also be reduced by vibration.

 Upon leaving the die, there is a decrease in pressure acting on the mixture, which allows the material to expand slightly and return to a state of somewhat less optimized particle packing. In this case, in turn, partial rarefaction occurs in the capillaries and significant surface tension forces arise that hold the hydraulically settable material in its entirety. A sharp drop in pressure (and a decrease in shear forces) increases the viscosity of the material, which, combined with a high yield strength at zero shear forces, reduces the concentration of water available for particle lubrication and, as a result, leads to an immediate increase in form stability.

 The rheological characteristics of the hydraulically settable mixture can also be changed by introducing other additives into the cement mixture, such as reagents for modifying the rheological characteristics based on cellulose, starch, protein or synthetic organic substances, which increase the yield strength of the mixture with a slight increase or decrease in viscosity to the state of complete lack of workability. Under the conditions of high shear forces occurring in a screw or piston extruder, the high yield strength decreases, the plastic viscosity temporarily decreases, and the mixture temporarily acquires the ability to flow. After the extrusion of the hydraulically settable material is complete and shear forces cease, the reagent for modifying the rheological characteristics promotes the formation of a more coherent and form-stable extrusion product. Thus, the reagent for modifying the rheological characteristics contributes to the creation of a hydraulically settable mixture exhibiting shear thinning, i.e. thixotropic or pseudo-plastic behavior, or material showing an apparent decrease in viscosity due to shear stresses, including stresses due to pressure and vibration.

In addition to imparting the required rheological characteristics to the mixture, optimizing the packing of the particles of the mixture can significantly increase the final strength of the cured product by reducing the concentration of water and air in the hydraulically cured matrix. In accordance with the strength equation below, the compressive strength of a cured cement product is inversely proportional to the concentration of water and air in between the particles. (In this formula: σ is the compressive strength of the cured cement product: k represents the maximum theoretical strength in the complete absence of water and air between the particles, which is usually about 300 - 500 MPa, although in some cases it can reach 800 MPa ( for example, if the extrusion product is cured in an autoclave): V _c is the volume of cement: V _w is the volume of water: and V _a is the volume of air or voids between the particles of the cement mixture):
σ = k [V _c / (V _c + V _w + V _a )] ² MPa
For ordinary unconsolidated cement paste, k = 340 MPa, whereas in a system with a high degree of compaction, k = 500 MPa. Therefore, the value of k depends on the applied technological method, but is constant when using the same method. Typically, a decrease in the concentration of air and water in a hydraulically settable mixture increases the strength of the final cured material. A decrease in the concentration of water and air, together with an improvement in the workability of the hydraulically settable mixture, can be achieved by increasing the packing density of the particles, as described in more detail below. In addition, the increase in pressure during extrusion and corresponding compression during operation also significantly reduces the air volume between the particles while maintaining adequate fluidity in the event of a water shortage (reduction in water volume).

 If the packing density of the particles of the hydraulically settable mixture is optimized to the upper limit of the range indicated in the present description, then a relatively high extrusion pressure is applied to remove almost all the air contained between the particles from the mixture, and initially a very small amount of water is introduced into the mixture. In this case, using extrusion, it is possible to obtain industrial products with a hydraulically settable matrix, in which the compressive strength exceeds 500 MPa and even reaches 800 MPa (for example, when processed in an autoclave).

 It is known that in laboratory conditions high-strength concrete products were manufactured with a low content of water and air between particles. However, in this case, isostatic pressing (often with dry packaging) was usually used under particularly high pressure, usually by pressing under high pressure in excess of about 70 MPa. However, these methods cannot be adapted for the economical mass production of cement materials, as well as for the manufacture of any products other than items of the simplest or primitive form. These methods are clearly unsuitable for continuous mass extrusion of form-resistant hydraulically settable products, such as can be made using the compositions and methods of the present invention. In addition, compared to conventional pressing processes, extrusion is a more continuous method for mass production of certain products, for example relatively narrow products of large lengths with a constant cross-sectional shape and constant dimensions.

 In addition to incorporating continuous fibers into the hydraulically settable matrix, as described in more detail below, it may also be desirable to extrude the hydraulically settable mixture in conjunction with other materials, for example to provide a layered structure or to produce an extrusion product having, inside or on the surface of the hydraulically settable matrix other materials are applied. Together with the hydraulically settable mixtures of the present invention, other hydraulically settable mixtures (often having other or complementary properties) can be extruded; fiber mats, graphite (for the manufacture of pencils), covering materials, polymers, clays, as well as continuous strips, wire or sheets of almost any other materials (such as metal). It has been found that, for example, by combining a hydraulically settable sheet and a fiber mat by coextrusion, the final product exhibits mutually enhanced strength, toughness and other desirable properties.

 After extrusion of the hydraulically settable mixture to obtain the desired shape, the product can be cured while maintaining the shape given by extrusion. The curing process can be accelerated by heating the subject, for example, under conditions of controlled high relative humidity, or in an autoclave under high pressure. Alternatively, other operations or manipulations can be carried out with the extruded profile, such as passing an extruded sheet between a pair of rolls in order to reduce its thickness and (or) improve the surface quality of the sheet. The extrusion product can also be bent, bent, cut or subjected to additional pressing using any known process of pressing and stamping in order to obtain a wide variety of objects or profiles.

B. Extruded Profiles and Products
The terms “extruded profile”, “extruded product” and “hydraulically settable product” as used in the present patent specification and the attached patent claims include any profiles or products formed by continuous extrusion and continuous fiber reinforcing of the hydraulically settable compositions of the present invention, including those profiles and products that are currently known and those that will be developed in the future. An exemplary but non-exhaustive list of extruded profiles and products that can be manufactured according to the present invention includes rectangular, square, elliptical or cylindrical rods and beams, reinforcement for concrete, pipes, hollow cylinders, straws (for cocktails), cylinders, multi-cell constructions, slabs, I-beams, two-by-four-inch cross-sections, window frames, bricks, roofing tiles and pencils.

 In addition, it is assumed that the terms "extruded product", "extruded profile" and "hydraulically settable product" also include all of the preceding profiles or products that were originally molded by extruding the compositions of the present invention and reinforcing the extrudable product with continuous fibers, but were subsequently manipulated , changes or other operations to form other profiles or products. For example, an extruded rod or pipe that was originally straight, can be bent to form a rod. Both straight and curved rods or pipes are included in the scope of the present invention and fall within the definition of the terms “extruded article”, “extruded product” and “hydraulically settable product”. It is also intended that these terms include any products or forms that are components of another product, regardless of whether such a product is within the scope of this patent or not. While a combination of extruded products or a combination of extruded products with any other products may have independent properties to be patented, that part that is manufactured by the methods and means of the present invention also falls into the category of terms “extruded object”, “extruded product” and a "hydraulically settable product", like any combination of product components.

C. Product development using microstructural engineering
As mentioned above, the hydraulically settable compositions of the present invention were developed using microstructural engineering methods and material technology, which allowed to give the microstructure of the materials of the hydraulically settable matrix the desired desired qualities, provided taking into account the cost and other production factors. In addition, the use of microstructural engineering instead of the traditional trial and error method, manufacturing and testing, allows a much more efficient way to develop hydraulically set materials with the characteristics of strength, weight, thermal insulation, cost and environmental neutrality required for the extrusion of various hydraulically set items in much more effective ways than previously known.

 For the development of any specific products, you can use a huge variety of different types of raw materials, the number of which is estimated to be about fifty to eighty thousand. The raw materials can be materials of various broad classes, such as metals, polymers, elastomers, ceramics, glass, composite materials and cements. Within a certain class, there is some similarity of characteristics, processing methods and applications. For example, ceramics has a high elastic modulus, while for polymers this value is low; metals can be shaped by casting and forging, while composite materials require layering or special molding methods; Known hydraulically settable materials, including those made from hydraulic cement, typically have low flexural strengths, while elastomers have high flexural strengths.

 However, the division of the characteristics of materials into classes poses a certain danger; this can lead to narrow specialization (when the metallurgist knows nothing about ceramics) and to conservative thinking ("we use steel because we always used it"). It was precisely the narrow specialization and conservative thinking that limited the possibility of considering the use of hydraulically settable materials for the manufacture of various products, such as extruded profiles, including thin-walled, complex profiles, or products with tight tolerances.

 Nevertheless, after realizing the fact that hydraulically settable materials have a wide range of applications and can be created using microstructural engineering methods, the possibility of their use for the manufacture of various possible products becomes obvious. Compared to other traditional materials, hydraulically settable materials have the added advantage that they acquire their characteristics under relatively soft, gentle and economical processing. (For other materials, high energy costs, strong heating or harsh chemical treatment, which significantly affects the components of the materials) are required. Moreover, with the right choice of composition and technology, some non-hydraulically settable materials, such as continuous fibers, can be incorporated into the materials of the present invention without prejudice, resulting in a surprisingly good combination of qualities.

 The composition of the mixtures of the present invention was developed and refined, first of all, taking into account the main limitations dictated by the designation, and then due to such selection of materials that would maximize the characteristics of the components. However, at all stages of this process, it is important to remember the need to create such products that can be manufactured in a cost-effective manner.

 The main limitations when choosing materials are due to the design characteristics of the component, which are critical for creating a successful product. In the case of an extrudable product, such basic restrictions include requirements for weight, strength (compressive, tensile, bending and tearing under the influence of internal or external pressure), impact strength and other operational characteristics, while maintaining the cost at a level close to production costs , for example, plastic, wooden, clay and metal analogues of these products.

 As mentioned above, one of the problems associated with previously used hydraulically settable materials was that they were usually poured into the mold, compacted and then left in the mold for solidification, setting and curing for a long time - several days or even weeks . Specialists generally agree that it takes at least a month to achieve the optimum strength of traditional concrete products. Even with the use of expensive “setting accelerators”, this hardening process continues for several days. Such periods of time usually lead to the inappropriateness of economical mass production of hydraulically settable products provided by the present invention.

 As a result, an important quality of the present invention is the fact that a hydraulically set extruded mixture to obtain the desired profile or product will remain in its wet state and without external supports (i.e., maintain its weight when exposed to small forces such as gravity and forces arising from the movement of products along the process chain). Further, from a production point of view, to ensure production efficiency, it is important that the extruded product quickly (within a few seconds) acquire sufficient strength to enable the usual manipulations used in the production process, even though the hydraulically settable mixture is still in a wet state and not completely hardened.

Another advantage of the method of using microstructural engineering and material technology of the present invention is the possibility of developing compositions in which the cross sections of the structural matrix have a more uniform structure than that which was usually achieved by known methods. Ideally, two 1-2 mm ³ samples taken from a hydraulically settable structural matrix should have almost the same amount of particles of a hydraulically settable binder, a hydraulically settable binder gel, aggregates, short and long fibers, a reagent for modifying rheological characteristics and other additives.

 In its simplest form, the process of applying material technology and microstructural engineering in the development of hydraulically settable material involves characterizing, analyzing, and modifying (if required): (a) aggregates, (b) particle packaging, (c) rheology of the system, and (d) processing methods and energy intensity of the production system. When characterizing aggregates, the average particle size, the density of the natural packing of the particles (which is a function of the size distribution and particle morphology) are determined and the particle strength is checked. (Unreacted or previously reacted hydraulically settable binder particles can be considered as aggregate).

 Given this information, particle packing can be predicted using mathematical models. It has been found that particle packaging is a major factor in determining the desired characteristics of the final product, such as workability, shape stability, shrinkage, bulk density, thermal insulation, tensile strength, compression and bending, elasticity, durability and cost optimization. Particle packaging is influenced not only by the nature of the particles and aggregate, but also by the volume of water and its interdependence with the interlayer empty volumes of the packed aggregate.

 The rheology of the system is a function of both macro-rheology and micro-rheology. Macroreology describes the relationship between solid particles, determined by the nature of their packaging. Microreology is a function of those components of the system that have the qualities of a lubricant. By modifying lubricants (which can be water, reagents for modifying rheological characteristics, plasticizers, dispersants or other materials and their combinations), the viscosity and yield strength can be changed. Microreology can also be physically altered by changing the shape and size of particles, for example, by using chopped fibers, mica plates, rounded silica particles, rhombic micrograin silica, or crushed, faceted, or granular particles of a hydrated binder that will interact differently with lubricants .

 Finally, you can modify the manufacturing process to adjust the balance between workability and dimensional stability. As a rule, a decrease in the viscosity of a mixture increases its workability, while an increase in the yield strength increases the shape stability of the material after extrusion. As applied to the present invention, the optimal approach, as a rule, is to maintain the minimum required yield strength while minimizing viscosity. Forming or deformation of the material takes place only if a force exceeding its yield strength is applied to the hydraulically settable mixture.

 The yield strength and, therefore, the shape stability of the extrusion product can also be increased using chemical additives (for example, a reagent for modifying rheological characteristics), or additional energy (for example, heating the extrusion apparatus or extruded materials). For example, heating the material during extrusion can activate a starch additive, which will increase the yield strength of the material after extrusion. In addition, heat accelerates the hydration reaction, which takes place with the participation of a hydraulically settable binder and water, and the rate of this reaction sometimes increases by 10–20 times compared to the usual one. It is this discovery of the possibility of manipulating the composition of hydraulically settable mixtures in order to quickly achieve the form stability of the compositions while ensuring high fluidity in the molding process and makes the present invention such a significant achievement in the art.

 Below is a description of how each of the constituent materials of the hydraulically settable mixture and each of the process parameters contribute to the satisfaction of the basic structural requirements for extrudable hydraulically settable mixtures and enable the production of various products from such mixtures. The following examples of specific formulations demonstrate how maximizing the performance of each component contributes to a combination of required qualities.

D. Hydraulically settable materials
The materials used to make the extrudable articles of the present invention gain strength as a result of the chemical reaction of water and a hydraulically settable binder such as hydraulic cement, calcium sulfate hemihydrate (gypsum) (which is sometimes mixed with gypsum anhydrite, known as "anhydrite") or other materials that harden under the influence of water. Even materials such as furnace and blast furnace slag, fly ash or silica fume can also be activated and act as a “hydraulically settable binder”.

 The term "hydraulically settable materials", as used in the present patent specification and the patent claims appended thereto, includes any materials in which the structural matrix and strength characteristics are determined by the hardening or setting of the hydraulically settable binder. These include cementitious materials, plastering mortars, and other hydraulically settable materials that meet the definition given here. The hydraulically settable materials used in the present invention should be distinguished from other cements or binders, such as polymerizable water-insoluble organic cements, adhesives, or adhesives.

 The terms “hydraulically settable materials”, “hydraulic cementitious materials” or “cementitious materials” as used herein are intended to generically refer to compositions and materials containing both a hydraulically settable binder and water, irrespective of the degree of hydration or curing that has already occurred. . Therefore, the term "hydraulically settable materials" is intended to include both hydraulic pastes or hydraulically settable mixtures in their raw form (i.e., uncured state), and hardened hydraulically settable or concrete products. Hydraulically settable wet materials may also be referred to as "hydraulically settable mixtures".

1. Hydraulically settable binders
The terms “hydraulically settable binder” or “hydraulic binder” as used in the present patent specification and the patent claims appended thereto include any inorganic binders (such as hydraulic cement, gypsum hemihydrate, calcium oxide and mixtures thereof) that acquire strength characteristics and hardness as a result of a chemical reaction with water, and in some cases, with carbon dioxide contained in air and water. The terms “hydraulic cement” or “cement” as used in the present patent specification and the patent claims appended thereto include the original clinker, as well as broken, crushed, ground and processed clinker at various stages of formation of cement powder with different particle sizes.

 Examples of cements known in the industry are: various Portland cements (including conventional Portland cement without gypsum), MDF cement, DSP cement, Densit cement, Pyrament cement, and calcium aluminate cement (including cements based on calcium aluminate without setting agents), plastering materials, silicate cements (including β-dicalcium silicates, tricalcium silicates and their mixtures), gypsum cements, phosphate cements, high alumina cements, highly fine-grained cements Options, slag cements, cements, magnesium oxychloride, and aggregates coated osobomelkozernistymi cement particles. The term "hydraulic cement" also includes other types of cement known in the industry, such as α-dicalcium silicate, which acquires the properties of a hydraulic binder under hydration conditions provided by the present invention.

The main chemical constituents of cements, for example, Portland cement, are CaO, MgO, SiO ₂ , Al ₂ O ₃ , Fe ₂ O ₃ SO ₃ in various combinations and proportions. As a result of a number of complex reactions in the presence of water, these materials form insoluble calcium silicate hydrates, carbonates (with the participation of CO ₂ present in the air and added water), sulfates and other salts or substances, including calcium and magnesium, aluminum and iron, together with their hydrates . Such reaction products include tricalcium aluminate, dicalcium silicate, tricalcium silicate and tetracalcium ferrite alumina. It is assumed that aluminum and iron are embedded in complex complexes within the aforementioned materials. A cured cement product is a complex matrix of insoluble hydrates and salts forming complex bonds similar to those in stone. This material has a high inertness, as well as physical and chemical characteristics similar to those of natural stone and earth.

 Gypsum is also a hydraulically settable binder that can undergo hydration and become a hardening binder. One hydrated form of gypsum is calcium sulfate hemihydrate, commonly referred to as "gypsum hemihydrate." The hydrated form of gypsum is calcium sulfate dihydrate, commonly referred to as "gypsum dihydrate". Calcium sulfate hemihydrate can also be mixed with calcium sulfate anhydride, which is commonly called "gypsum anhydrite" or simply "anhydrite."

 Although gypsum binders or other hydraulic binders, such as calcium oxide (quicklime), usually do not have the same strength as hydraulic cement, in some areas of application, high strength may not be as important as other characteristics (for example, solidification speed) . From an economic point of view, gypsum and calcium oxide have an advantage over hydraulic cement, since their cost is slightly lower.

 In addition, it is known that gypsum hemihydrate hardens or hardens much faster than conventional cements. Indeed, when used in the framework of the present invention, it is cured and hardened to almost a maximum of about thirty minutes. Therefore, gypsum hemihydrate can be used alone or in combination with other hydraulically settable materials of the present invention. It was found that the addition of gypsum hemihydrate to a hydraulically settable mixture containing hydraulic cement as a binder makes it possible to obtain a mixture with a significantly reduced ratio of water to cement and, therefore, increased strength according to the strength equation.

 Terms such as “hydrated” or “cured” as applied to hydraulically settable mixtures, materials or matrices refer to the degree of completion of the water-catalytic reaction that is sufficient for the hydraulically settable product to acquire a significant portion of its potential final maximum strength. However, hydration of hydraulically settable materials can continue for a long time after these materials acquire substantial hardness and a significant portion of their ultimate maximum strength.

 Terms such as “wet” or “wet state” are used to describe hydraulically settable mixtures that have not yet acquired a significant part of their final strength, regardless of the methods used for such hardening, whether forced drying, curing or other methods. Hydraulically settable mixtures are “wet” or “wet” immediately before they are shaped and immediately afterwards. The moment when the hydraulically settable mixture ceases to be “wet” or “in a wet state” is not necessarily a clearly defined boundary moment, since such mixtures usually acquire a substantial part of their full strength only gradually over time. Of course, hydraulically settable mixtures can exhibit an increase in “wet strength” and still remain “raw”. For this reason, the present description often refers to the stability of the form of a hydraulically settable material in a wet state.

 As mentioned above, preferred hydraulically settable binders include white cement, Portland gray cement, extra fine-grained cement, high alumina cement, slag cement, gypsum hemihydrate and calcium oxide, mainly due to their low cost and suitability for the present process invention. This list of cements is by no means exhaustive and is not intended to limit the types of binders that may be useful in the manufacture of containers from hydraulically settable materials within the scope of the patent claims appended hereto. It has been found that gray Portland cement, to a greater extent than other types of cement, contributes to the cohesive strength of the crude hydraulically settable mixture.

 Other types of hydraulic cement based formulations include those in which carbon dioxide is mixed with hydraulic cement and water. Hydraulic cement based formulations made in this way are known for their ability to more quickly achieve a high wet strength state. This type of hydraulic cement based formulation is discussed in US Pat. No. 5,232,496, issued August 3, 1993 to Dr. Hamlin M. Jennings and Simon K. Hodson, according to which water and hydraulic cement are mixed in the presence of a carbonate source selected from the group of materials. including carbon dioxide, carbon monoxide, carbonate salts and mixtures thereof. For purposes of disclosure, the above patent is incorporated into this application by this reference.

2. Hydraulic paste
In each of the embodiments of the present invention, the key element is a hydraulic paste (including cement paste), which gives the container the ability to "solidify" and acquire strength characteristics. The term "hydraulic paste" refers to a mixture of a hydraulically settable binder with water. More specifically, the term “cement paste” refers to a mixture of hydraulic cement and water. The terms “hydraulically settable”, “hydraulic” or “cement” mixture refer to a paste made from a mixture of hydraulic cement and water, to which aggregates, fibers, reagents for modifying rheological characteristics, dispersants or other materials are added, and this mixture may be found in raw , and in a frozen (cured) state. Other ingredients added to the hydraulic paste serve to change the characteristics of both the non-solidified and the final cured product, including, but not limited to, compressive strength
and tension, shrinkage, flexibility, bulk density, color, porosity, surface quality and texture.

 Although a hydraulic binder is a component that allows a hydraulically settable mixture to harden, harden and provide most of the strength characteristics of the material, some hydraulic binders also contribute to the acceleration of cohesion and wet strength. For example, it is known that particles of hydraulic cement at the beginning of a reaction with water undergo hardening even before they are cured, which can help improve the internal cohesion of the mixture.

 It is believed that aluminates, such as those that prevail in the composition of gray Portland cement (in the form of tricalcium aluminates or tetracalcium alumina ferrites) are responsible for colloidal interaction between cement particles in the early stages of hydration. This in turn causes a certain level of flocculation (flocculation) and gelation between cement particles. It has been shown that the effects of gelation, colloidization, and flocculation of such binders improve the formability characteristics (i.e., ductility) of hydraulically set mixtures made using these binders.

 The percentage of hydraulically settable binder in the mixture varies depending on the type of other added components. However, the hydraulically settable binder is preferably administered in a concentration of about 1 to 90% by weight of the wet hydraulically settable mixture, more preferably in the range of about 8% to 60%, and most preferably in the range of about 10% to 45%. The present description and the examples given therein make it clear that such a wide range of concentrations serves to produce a wide variety of products that can be molded by extrusion of a hydraulically settable mixture.

 Notwithstanding the foregoing, it should be borne in mind that all concentrations and quantitative characteristics critically depend on the qualitative characteristics required for the final product. For example, for a structure with a very thin wall (only 0.05 mm) where high strength is required, it may be more economical to use a very high concentration of hydraulic binder with little or no filler additive. In this case, it may also be desirable to include a large number of fibers to give the product flexibility and toughness.

 Another important component of hydraulic paste is water. By definition, water is an essential component of the hydraulically settable materials of the present invention, the hydration reaction occurring between the hydraulically settable binder and water makes it possible to obtain reaction products that give the hydraulically settable materials the hardening and strength properties.

 In most applications of the present invention, it is important to carefully control the ratio of water to cement to obtain a hydraulically settable mixture which, after extrusion, will be self-supporting in a wet state. However, the amount of water used depends on a number of different factors, including the types and volumes of the hydraulic binder, aggregates, fiber materials, reagents for modifying the rheological characteristics and other materials or additives in the hydraulically settable mixture, the extrusion modes used, and the specific types and characteristics of manufactured products.

 The preferred amount of water for each application mainly depends on two key variables: (1) the amount of water required to react with the binder and to hydrate it; (2) the amount of water required to give the hydraulically settable mixture the necessary rheological characteristics and workability properties.

 To ensure the required workability properties of the crude hydraulically settable mixture, the amount of water introduced should usually be sufficient to wet all individual components, as well as to (at least partially) fill the gaps or voids between the particles (including, for example, binder particles, fillers and fiber materials ) If water-soluble additives are included, then sufficient water should be added to dissolve these additives or conduct other reactions with them). In some cases, for example, in the case of the addition of a dispersant, workability can be improved by reducing the amount of water used.

 The water concentration should be carefully balanced so as to ensure sufficient workability of the hydraulically settable mixture, not forgetting that reducing the water content can increase both the wet strength and the final strength of the cured extrusion product. The corresponding rheological characteristics required to meet these requirements can be expressed as the yield strength. In order for the hydraulically settable mixtures to acquire adequate wet strength and shape resistance after extrusion to give them the desired product shape, the yield strength of the hydraulically settable mixture should preferably be at least 2 kPa, more preferably at least 10 kPa, and most preferably at least 100 kPa It should be understood that these values are preferred minimum values. There is no maximum value for the yield strength, and depending on a number of factors, such as water deficiency in the mixture, particle morphology, reagent concentration for modifying the rheological characteristics in the mixture, the yield strength can be much higher. The required level of yield strength can (and should) be adjusted and optimized depending on the specific form of the extruded product.

Since the hydraulically settable mixtures of the present invention exhibit the property of thinning under shear stresses, it is not possible to indicate any particular preferred viscosity value, but it can only be stated that the viscosity of the mixture must be sufficient to ensure form stability, but at the same time low enough to ensure flow mixtures in an extruder. In general, however, it can be pointed out that the effective viscosity will usually be at least 10 ⁷ Pz at a shear rate of 0 s ^-1 , at least 10 ⁴ Pz at a shear rate of 20 s ^-1 and at least about 2 • 10 ² Pz at shear rate 1000 s ^-1 .

 One skilled in the art will understand that if a large number of aggregates or other water-absorbing additives are included, the ratio of water to hydraulically settable binder must be increased in order to maintain workability and sufficient water to hydrate the hydraulically settable binder. This fact is due to the fact that an increase in the concentration of aggregates leads to an increase in the volume of gaps between particles or voids that must be filled with water, the concentration of which is expressed as a fraction of the volume of a hydraulically settable binder. Porous aggregates can also absorb significant amounts of water since they have a large volume of voids. Given the above defining requirements, typical hydraulically settable mixtures of the present invention will have a water to cement ratio in the range of about 0.05 to 4, preferably about 0.1 to 1, and most preferably about 0.15 to 0. 5.

 Due to the increased packing density of the hydraulically settable binder particles in a typical mixture of the present invention, the density of the hydraulic paste in the hydraulically settable mixture is preferably (when high strength is desired) at least 2.2, more preferably at least 2 , 5, and most preferably at least about 2.6.

 It should be noted that a hydraulically settable binder exerts an internal drying effect on the hydraulically settable mixture, since the binder particles chemically react with water and reduce the amount of free water between the particles. This effect of internal drying can be enhanced by the inclusion of quick-reacting hydraulic binders, such as gypsum hemihydrate, together with a slower-reacting hydraulic cement.

3. Water scarcity
In many cases, the amount of water required to hydrate the binder as well as to give the hydraulically settable mixture the required rheological characteristics can be more accurately determined using volume percent or the concept of "water shortage". The level of water scarcity is determined by subtracting the volume of free water in the intermediate voids from the total volume of intermediate voids and dividing the resulting difference by the total volume of intermediate voids.

water shortage = (V _voids - V _water ) / V _voids
As an example and to illustrate the concept of water scarcity, it can be pointed out that a hydraulically settable mixture, in which water was added, can nevertheless have a 100% water deficiency (i.e. the complete absence of water in the intermediate voids) if all the water was absorbed in pores of the aggregate material, or reacted with a hydraulically settable binder.

 Of course, it should be borne in mind that the amount of water actually reacted with the hydraulically settable binder at any given time after mixing the hydraulically settable binder with water will usually be significantly lower than the calculated stoichiometric equivalent of the volume of water required for almost complete hydration of the binder. Due to the kinetics of the hydration reaction, water does not completely react immediately with a hydraulically settable binder, and such a reaction is carried out gradually, usually during the curing period after extrusion of the material.

 Consequently, water from a theoretical stoichiometric equivalent volume that has not reacted with a binder, as a rule, can fill the gaps or voids between the particles (if it is not absorbed by the particles of the filler material). Water that has not reacted chemically with a hydraulically settable binder can be classified as gel water or as capillary water. Both forms cause a decrease in the strength of the final cured material, and therefore, their concentration should be minimized if possible. Since the amount of water available to fill the gaps directly affects the workability and rheological characteristics of the hydraulically settable mixture, the amount of unbound stoichiometric water available to fill the gaps and lubricate the particles at any given time after mixing should be determined, given that the initial moment, almost all the water added to the mixture is in a free state, since the hydration reaction proceeds slowly.

 Some factors that determine the percentage of the estimated stoichiometric equivalent volume of water that actually reacted with a hydraulically settable binder include the reactivity (reaction rate) of the binder, the temperature of the mixture, the particle size of the binder, the degree of mixing, the wettability of the components of the entire mixture, and the time elapsed after introducing water into the mixture.

 For example, hydraulically settable binders with a high reaction rate will absorb existing water or react with it much faster than binders with a low reaction rate. As in the case of most other reactions, an increase in temperature usually leads to an increase in the reaction rate of all hydraulically settable binders and, therefore, to an acceleration of water absorption by the binder.

 In addition, hydraulically settable binders with small particles will also react faster with water, as their total surface area will be larger, which speeds up contact and reaction with water. It is clear that the reaction rate of the hydraulically settable binder particles with water depends on the degree of mixing. With more thorough mixing of the mixture, the contact between water and binder particles improves, which accelerates their reaction.

 The degree of completion of any reaction that has not reached equilibrium also depends on the time elapsed since the mixing of the reacting substances. Obviously, a hydraulically settable mixture in which a hydraulically settable binder has been in contact with water for a long time will show a higher degree of completion of the reaction between the water and the binder. However, if a dispersant is added, increasing the mixing time leads to an increase in the specific surface area of the particles adsorbing the dispersant, which allows for a short time to increase the fluidity of the mixture. Typically, the main setting of hydraulic cement takes about 5 hours.

 In addition to the dynamics of the reaction between the hydraulically settable binder and water, other components of the hydraulically settable mixture can also to some extent affect the absorption of water or its reaction with the binder particles. Some additives, such as water-soluble reagents to modify rheological characteristics, will compete with the binder particles and actually absorb some of the available water.

 In addition, other additives, such as dispersants, can slow down the reaction between water and hydraulically settable binder particles. When formulating the composition of any particular mixture, the effect of these components or reaction conditions on increasing or decreasing the reaction rate between water and hydraulically settable binder particles should be carefully considered. However, any person skilled in the art can predict the effect of a given component or reaction condition on the rate of reaction of water with a hydraulically settable binder, at least based on empirical observations.

 After determining the amount of water that will actually react with the cement, the next step is to determine the volume of “fill water” that should be added in addition to this reacted or absorbed water. Filling water is water that can be used to fill gaps or voids between particles and which directly affects the workability of a hydraulically settable mixture. The preferred amount of fill water required is determined by a combination of various factors, including the packing density of the particles in the mixture, the compressibility of the mixture, and the pressure exerted on the mixture in the extruder.

 Knowing the value of the packing density of the particles allows us to determine the volume of the intermediate space in the uncompressed mixture, which at the initial stage will be filled with filling water. Knowing the compressibility of the mixture and the pressure that will act on the mixture, it is possible to calculate the expected reduction in the intermediate volume at the time when the hydraulically set mixture will be subjected to this pressure during the extrusion process.

 With a reduced particle packing density, the gap volume, expressed as a percentage of the total mixture volume, will be high, and more water will be needed to fill this volume. Conversely, with a high packing density of particles, the gap volume, expressed as a percentage of the total mixture volume, will be low, and less water will be needed to fill this volume. Methods for optimizing particle packing density will be discussed below.

 Similarly, if the hydraulically settable mixture is subjected to a large pressure during the extrusion process, the compression (compaction) step will lead to a more significant reduction in the volume of the intermediate space, which in turn means that a smaller initial volume of filling water will be required to provide the required rheological characteristics. In addition, a reduction in the volume of introduced water (increasing water deficit) allows the particles to be pressed more densely to each other during the compaction process, which will reduce porosity and increase the density and strength of the final product.

 Conversely, if the hydraulically settable mixture is subjected to small pressure during the extrusion process, the compaction step will lead to a less significant reduction in the volume of the intermediate space, which in turn means that a larger initial volume of filling water will be required to provide the required rheological characteristics. Some aggregate materials, such as sand, have relatively low compressibility. (The value of pressure to which a hydraulically settable mixture can be subjected without breaking the particles of filler material contained in it is determined by the compressive strength of the filler particles).

 The solution is to choose just such a volume of water that will ensure almost complete filling of the intermediate space during compression of the mixture during the extrusion process. The addition of water in a volume exceeding the volume necessary to fill the gaps during compression of the extrudable mixture will lead to a decrease in both the raw strength of the extrusion product and the final strength of the cured material (according to the strength equation).

 In view of the above, it was found that adequate workability of a hydraulically settable mixture subjected to high pressure can be achieved with a shortage of water introduced into the mixture. The volume of water can be expressed in volume percent, and in case of deficiency it will be less than the volume of the intermediate space, which is determined by subtracting the natural packing density of the particles from 1. For example, if the natural packing density is 65%, then the deficiency of water in the mixture will occur if when the concentration of water in the mixture will be less than 35% of the volume of the mixture. The volume of water required to ensure adequate workability will to some extent depend on the ratio of the concentrations of the components of the mixture, such as hydraulically settable binder particles, filler particles and fibers. However, in the general case, the volume of water required to obtain a hydraulically settable mixture with the required rheology and ductility characteristics is determined not by the type or ratio of components, but by the total volume and packing density of the components.

 Thus, the volume of water introduced can be expressed as a "water shortage" that exists before the mixture is compacted during extrusion. In mixtures where the required rheological characteristics are provided taking into account the principles of particle packing and water deficiency, the degree of water deficiency can fluctuate in a larger range, from about 1% to 90%. Since the preferred degree of water deficiency will depend significantly on many other variables, such as the components of the hydraulically settable mixture, the rheological characteristics of the mixture and particle packing efficiency, as well as the required characteristics of the extrusion product, it is not possible to indicate a narrower range for the degree of water deficiency. If a reagent is used to modify the rheological characteristics, it becomes possible to extrude the mixture with an excess volume of water (or with a "negative" water deficit).

 However, for any given mixture it is usually preferable to include the minimum amount of water necessary to ensure the flow of the mixture under a given extrusion pressure, and also to obtain sufficient internal adhesion force so that the product retains its shape after extrusion of the mixture. The minimum amount of water necessary to ensure the flow of a hydraulically settable mixture can be further reduced by the addition of impurities such as plasticizers or dispersants, as described in more detail below. When using particularly small volumes of water, in some cases, it may be necessary to tablet a hydraulically settable mixture to increase the processability of extrusion of the mixture.

 However, as a general rule, you can specify that a mixture with an increased water deficiency will usually be tougher and less ductile at the initial stage. Conversely, a mixture with a reduced water deficit will usually be less viscous and more plastic at the initial stage. The level of stiffness, viscosity, or ductility (workability) required for any given mixture will depend on the particular extrusion process used. Of course, during the extrusion process, when the hydraulically settable mixture is compacted, the degree of water deficiency will decrease (sometimes quite significantly). In some cases, this indicator can reach or even exceed the value of 0%. (A negative value of the degree of water deficiency means that there is excess or excess water; i.e., the volume of water exceeds the volume of intermediate voids between solid particles compacted during the extrusion process).

 However, hydraulically settable mixtures with high particle densities (as opposed to mixtures with low particle densities) can generally have a high degree of water deficiency and can still be easily extruded under pressure. For example, if the packing density of a hydraulically settable mixture with a natural packing density of 50% can increase to 65%, the packing density of a hydraulically settable mixture with a natural packing density of 80% can increase to 95%. In the first case, the decrease in the volume of the intermediate space (from 50% to 35%) will be insignificant in comparison with the second case (from 20% to 5%), where this volume is reduced by four times. Therefore, a mixture with a higher particle packing density will demonstrate a significantly more significant decrease in the effective value of the degree of water deficiency.

 In some cases, it may be preferable to "excess water" (ie, more water than is required to fill the intermediate space) in order to reduce the viscosity and improve workability of the mixture. However, to provide immediate wet strength in such cases, it may be necessary to heat the surface of the extrusion product using a hot mold (die) to completely or partially remove the "excess water". In addition, you can add gypsum hemihydrate, which fully or partially reacts with excess water and thereby increase the shape stability of the extrusion product.

 If an increased volume of the reagent is added to the initial mixture to modify the rheological characteristics or dispersant in order to improve the workability of the hydraulically settable mixture, then the shape stability of the extruded object or profile can be improved, for example, by immediately passing the product through a tunnel furnace or a vacuum chamber. At the same time, part of the water is discharged from the surface of the product in the form of vapors or steam, due to which the volume of filling water is reduced, friction between particles is increased, and a rapid increase in shape stability is provided. However, overheating of the extrusion product or its excessively quick drying can lead to damage to the microstructure of the product and a decrease in its strength.

E. Reagents for modifying rheological characteristics
The inclusion of a reagent to modify the rheological characteristics allows to improve the plastic or cohesive characteristics of the hydraulically settable mixture, which makes it similar to the clay used for molding or extrusion. The reagent for modifying the rheological characteristics thickens the hydraulically settable mixture by increasing its yield strength without significantly increasing the viscosity of the mixture. An increase in the ratio of yield strength and viscosity increases the ductility of the material (like clay) and its suitability for shaping, while significantly increasing its subsequent shape stability or wet strength.

 You can use a number of natural and synthetic organic reagents to modify rheological characteristics with a variety of characteristics, including characteristics of low or high viscosity, yield strength and solubility in water. Although many of the rheological modification reagents provided by the present invention can be readily soluble in water, insoluble reaction products of hydraulic cement and water can envelop the rheological modification reagent and prevent it from being washed out of the extruded, hydraulically cured article exposed to water.

 The various reagents for modifying the rheological characteristics provided by the present invention can be roughly divided into the following categories: (1) polysaccharides and their derivatives, (2) proteins and their derivatives, and (3) synthetic organic materials. Polysaccharide reagents for modifying rheological characteristics can be further subdivided into (a) cellulose-based materials and their derivatives, (b) starch-based materials and their derivatives, and (c) other polysaccharides.

 Suitable reagents for modifying cellulose-based rheological characteristics include, for example, methyl hydroxyethyl cellulose, hydroxymethyl ethyl cellulose, carboxymethyl cellulose, methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxyethyl propyl cellulose, hydroxypropyl methyl cellulose and the like. The whole range of possible permutations is huge and cannot be given here, but it should be borne in mind that other cellulosic materials having the same or similar characteristics as the above materials will also work well.

 Suitable reagents for modifying starch-based rheological characteristics include, for example, amylopectin, amylose, marine gel, starch acetates, starch hydroxyethyl esters, ionic starches, extended molecular chain alkyl starches, dextrins, amine starches, phosphate starches and dialdehyde starches.

 Other natural reagents for modifying the rheological characteristics based on polysaccharides include, for example, alginic acid, phycocolloids, agar, gum arabic, guar gum, robinia bean gum, karaya gum and tragacanth gum.

Suitable reagents for modifying protein-based rheological characteristics include, for example, Zein ^® (prolamin extracted from corn), derivatives of collagen extracted from animal connective tissues, such as gelatin and glue, and casein (the main protein of cow's milk) .

 Finally, suitable organic synthetic plasticizers are, for example, polyvinylpyrrolidone, polyethylene glycol, polyvinyl alcohol, polyvinyl methyl ether, polyacrylic acids, salts of polyacrylic acids, polyvinyl acrylic acids, salts of polyvinyl acrylic acids, polyacrylamides, polyethylene ethylene oxide, polyethylene ethylene oxide latex, which may be a styrene-butadiene copolymer. The rheology of polymolinic acid changes significantly under the influence of heat, it can be used independently or in combination with any of the above reagents to modify the rheological characteristics.

Currently, a preferred reagent for modifying rheological characteristics is methylhydroxyethyl cellulose, available, for example, in the form of reagents Tylose ^® FL 15002 and Tylose ^® 4000, sold by Hoechst AG. located in Frankfurt. Germany. Reagents for modifying the rheological characteristics having lower molecular weight, such as Tylose ^® 4000, typically plasticizes or lubricates the mixture, it is not thickened, thereby increasing the yield during extrusion. Another useful reagent for modifying rheological characteristics is hydroxypropyl methyl cellulose sold under the trade name Methocel ^® .

 More specifically, reagents for modifying the rheological characteristics with low molecular weight contribute to the extrusion process by lubricating the particles. This reduces friction between the particles, as well as between the mixture and the adjacent surfaces of the extruder. Although a reagent for modifying the rheological characteristics based on methyl hydroxyethyl cellulose is preferred, it is also possible to use almost any non-toxic reagent for modifying the rheological characteristics (including all of the above) that possess the required characteristics.

Another preferred rheological modification reagent that can be used in place of or together with Tylose ^® and Methocel ^® is polyethylene glycol with a molecular weight of from 20,000 to 35,000. Polyethylene glycol has a greater role as a lubricant and gives the mixture a smoother consistency. For this reason, polyethylene glycol can more accurately be called a "plasticizer." In addition, it gives a smoother surface to the extruded hydraulically settable material. Stearates can also be added to lubricate the hydraulically settable mixture.

Finally, reagents for modifying rheological characteristics based on starch are of particular interest in the context of the present invention due to their relatively low cost in comparison with reagents for modifying rheological characteristics based on cellulose, such as Tylose ^® or Methocel ^® . Although starch gelding usually requires heat and / or pressure, starches can be modified and pre-reacted, which allows them to gel at room temperature. The fact that starches, like many of the other reagents listed above for modifying rheological characteristics, have various solubility, viscosity and rheology characteristics, allows you to carefully select the required qualities when determining the composition of the mixture, so that the mixture meets the specific technological and operational requirements for the desired extrudable product .

 The rheological modification reagent used in the hydraulically settable materials of the present invention may be included in a concentration of from about 0.1% to 5% by weight of the hydraulically settable mixture, excluding water, more preferably in a concentration of about 0.25 % to 2%, and most preferably in a concentration of from about 0.5% to 1%. Actual concentration will depend on the type of extruded product or product.

F. Placeholders
In the hydraulically settable mixtures of the present invention, aggregates known in the concrete industry can be used. In the case of extrusion of relatively thin-walled products and to preserve the possibility of extrusion of the mixture through small cross-section dies, the particle diameter of the aggregate used should generally be less than 25% of the minimum cross-sectional dimension of the structural matrix of the extruded product.

 Aggregates can be added to increase compressive strength, reduce cost by filling the volume, and to change the packing density of the particles of hydraulically settable materials obtained. Aggregates, in particular of lamellar type, are also useful for imparting a smoother surface. The compressive and tensile strength of the aggregate particles often affects the similar strength of the final cured article.

 Examples of useful aggregates include sand, dolomite, gravel, crushed stone, bauxite, basalt, granite, limestone, sandstone, glass beads, airgel, xerogels, marine gel, mica, clay, synthetic clay, alumina, silica, ash, silicon microparticles, lamellar alumina, kaolin, glass microspheres, ceramic spheres, gypsum dihydrate, calcium carbonate, calcium aluminate, xonotlite (crystalline calcium silica gel), unreacted cement particles and other mining materials. Hydrated and non-hydrated cement particles can also be considered as “aggregate” in the broad sense of the term, depending on their distribution and the nature of their incorporation into a hydraulically settable matrix. Even waste hydraulically settable materials, such as waste sheets, containers, plates or other objects of the present invention, can be used as a filler and hardener. Silicon microparticles and ash can also be added to reduce the porosity of the hydraulically settable mixture and increase its workability and cohesive strength.

 The amount of aggregate introduced will depend on the particular application or purpose and can vary significantly, from the complete absence of aggregate to the introduction of about 90% aggregate based on the weight of the crude hydraulically settable mixture, more preferably from about 3 to 70 weight. %, and most preferably from about 20 to 50 wt.%.

Clay and gypsum are particularly important aggregate materials because of their easy availability, extremely low cost, workability and ease of molding. Gypsum hemihydrate can also provide some of the bond and strength if added in sufficient quantities. Clay is a general term used to identify practical any kind of earth soil that forms a paste when mixed with water and cures after drying.The main components of clay are silica and alumina (use uemye for making pottery products, tiles, brick, and pipes) and kaolinite. To kaolin clays are anauxite (chemical formula Al ₂ O ₃ • 3SiO ₂ • 2H ₂ O) and montmorilonit (chemical formula Al ₂ O ₃ • 4SiO ₂ • H ₂ O) However, clays may contain a number of other substances, such as iron oxide, titanium oxide, calcium oxide, zirconium oxide and pyrite.

 In addition, although clays have been used for millennia and can harden even without firing, such unfired clays are susceptible to destruction by water, are extremely fragile and have low strength. However, clays are a good inexpensive aggregate for a hydraulically settable structural matrix.

 Similarly, gypsum hemihydrate also hydrates and forms calcium sulfate dihydrate in the presence of water. Therefore, gypsum has the characteristics of both aggregate and binder, depending on the type (hemihydrate or dihydrate) and the concentration of gypsum added to the hydraulically settable mixture.

 In accordance with the present invention, it is often preferred to include a plurality of aggregates of different types and sizes, which makes it possible to better fill the gaps between the aggregate particles and the hydraulically settable binder. Optimize particle packing density to reduce the amount of water required to provide the necessary plasticity during shaping by filling in volumes between particles that would otherwise be occupied by filling water, often referred to as “capillary water”. In addition, reducing the use of water increases the strength of the final cured article (according to the strength equation).

 To optimize packing density, aggregates with a wide variety of particle sizes ranging from about 0.01 μm to 4 mm can be used. (Of course, the acceptable particle sizes of various aggregates will be dictated by the desired purpose and thickness of the final product).

 In certain preferred embodiments of the present invention, it may be necessary to maximize the concentration of aggregates in the hydraulically settable mixture in order to maximize certain properties and characteristics of the aggregates (such as strength, low density or high thermal insulating properties). To maximize the concentration of aggregates, particle packing methods within a hydraulically settable material can be used.

 A detailed description of particle packing methods can be found in the following article, one of the co-authors of which is one of the authors of the present invention: Johansen, V. and Andersen, P.J., "Particle Packing and Concrete Properties". Material Science of Concrete II, pp. 111-147, American Society of Ceramics (1991). Further information is provided in the doctoral dissertation: Andersen, P.J. "Measurement and control in the concrete industry - The study of packaging and particle rheology." Danish Academy of Technical Sciences. For the purpose of disclosing information on particle packing methods, the above article and doctoral dissertation are incorporated herein by reference.

 A detailed description of the filler mixture selection methods and aggregate particle sizes required to meet the specified formulation criteria is given in the patent application of the United States of America, No. 08/109100, currently filed on August 18, 1993, to Dr. Per Just Andersen and Simon K. Hodson entitled "Structurally Optimized Compositions and Processes for Microstructural Engineering Cement Blends." For purposes of information disclosure, this application is incorporated herein by reference.

G. Fibers
As used in the present patent description and the attached patent claims, the terms “fibers”, “intermittent or short fibers” and “fiber materials” include both inorganic and organic fibers. Fibers are a special type of aggregate that can be added to a hydraulically settable mixture to increase cohesion, elongation in tension, bending ability, impact strength, impact strength, as well as bending, tensile and even compressive strength. Fiber materials reduce the likelihood of destruction of the extrudable hydraulically settable product in the case of the application of large transverse forces.

 As fibers included in the structural matrix, it is preferable to use natural fibers, such as cellulose fibers extracted from hemp, cotton, sisal, tree leaves, wood or trunks, or fibers made from glass, polyvinyl alcohol, synthetic fibers (for example, Kevlar (polyaramp) and polypropylene fibers), as well as fibers of silica, ceramic or metal. Glass fibers are preferably pretreated to be resistant to alkaline conditions.

Preferred fibers include glass fiber, synthetic fibers, hemp, bagasse, wood fibers (both hard and soft wood, such as mahogany or southern pine), ceramic fibers (such as alumina, silicon nitride, silicon carbide and graphite) and cotton fiber. It is possible to use paper fibers obtained in the processing of waste paper, but their use is less desirable, since the fibers are destroyed during the initial paper-making process, as well as in the recycling process. However, any other equivalent fibers imparting strength and flexibility are also within the scope of the present invention. Hemp fiber is available from Isarog Inc., Philippines. Fiberglass, for example, Cemfill ^® , is available from Pilkington Corp., England.

 The fibers used in the manufacture of the hydraulically settable materials of the present invention preferably have a high length to width ratio, since longer and narrower fibers can give the structural matrix greater strength without significantly increasing the volume and mass of the mixture. The ratio of the length and width of the fibers should be at least about 10: 1. preferably not less than about 100: 1, and most preferably not less than about 200: 1. However, while increasing the ratio of length and width of fibers provides an increase in the toughness and tensile strength of the final product, fibers with a smaller ratio of length and width are usually cheaper, provide a higher packing density of particles and are more evenly distributed inside the hydraulically settable mixture.

 The number of fibers added to the matrix of a hydraulically settable mixture will depend on the required characteristics of the final product, and the main criteria for choosing the number of fibers added to any composition are strength, toughness, flexibility and cost. In most cases, the fiber concentration is from about 0.5% to 30% by volume of the crude hydraulically settable mixture, more preferably from about 1% to 20% by volume, and most preferably from about 2% to 10% by volume. During the extrusion process, the fibers are usually oriented in the longitudinal direction, which increases the toughness of the product.

 However, it is clear that a very important factor in determining the amount of fibers used is their strength. The greater the tensile strength of the fiber, the smaller the number of these fibers should be added to obtain the same tensile strength of the final product. Of course, while some fibers have a high tensile strength, other types of fibers with a lower tensile strength may be more elastic. Therefore, to obtain a final product with maximization of various characteristics, such as high tensile strength and high elasticity, a combination of two or more fibers may be required.

 In addition, although ceramic fibers are usually much more expensive than natural fibers or fiberglass, in some cases, their use can be cost-effective due to their excellent tensile strength. Obviously, the use of more expensive material becomes more economical if the requirements for ensuring the minimum cost of the extrudable product are reduced, for example, in the case when the comparable product is made from a relatively expensive competing material.

 It should also be borne in mind that some fibers, such as southern pine and hemp fibers, have high tensile and crushing (crushing) strengths, while other fibers, like cotton ones, have lower strength but increased flexibility. If you want to provide both flexibility and high tensile and bursting strength, you can add a combination of fibers with different characteristics to the mixture.

 The strength characteristics of a hydraulically settable fiber-reinforced matrix substantially depend on how the fibers are fixed inside the matrix - “mechanical” or “chemical”. The term “mechanical fastening” refers to a predominantly mechanical interaction between fibers and other components of a hydraulically settable matrix, so that the adhesion or bonding forces between the fiber and the hydraulically settable matrix are generally less than the strength of the fiber. As a result, during deformation of the extrudable product, as a rule, the fibers are “pulled out” from their spatial position inside the hydraulically settable matrix, but the fibers do not break. This pulling effect, together with the additional friction energy that occurs when the fibers slip, increases the toughness and impact resistance of the extrudable product, which is partially due to the fact that the fibers cover any cracks caused by deformation, as well as the fact that in the case of arbitrary distribution of fibers inside a hydraulically settable matrix the crack propagation path is significantly extended. However, due to the effect of pulling out fibers with mechanical fastening, it can be assumed that such fibers will not significantly increase the tensile and bending strength of the extrudable product. As described in more detail below, a more significant increase in the tensile and bending strength of the extrudable product of the present invention is achieved by laying continuous fibers in the extrudable product.

 In contrast to the mechanical fastening of fibers, the term “chemical fastening” refers predominantly to the chemical interaction between the fibers and other components of the hydraulically settable matrix, so that the bonding or bonding forces between the fiber and the hydraulically settable matrix usually exceed the strength of the fiber. As a result, during the deformation of the extrudable product, “pulling out” of fibers does not occur, and the fibers remain firmly fixed inside the hydraulically settable matrix until the voltage applied to the object causes its destruction. At the time of the destruction of the extrudable product, chemically fixed fibers will rupture. As a result, fibers with chemical fastening can significantly increase the tensile strength (i.e., the maximum load before failure) and the bending strength of the extrudable product. However, chemically fixed fibers do not increase the toughness of the extrudable product, which, as a rule, undergoes complete destruction at maximum load.

 An increase in the degree of chemical affinity of the fibers with a hydraulically settable binder generally increases the degree of chemical fixation of the fibers within the hydraulically settable matrix. This can be achieved, for example, by coating various fibers with precipitated silica or ettringite. In addition, glass and alumina fibers, as a rule, exhibit a higher degree of chemical fixation in comparison with, for example, Kevlar or polypropylene fibers. In many cases, it is desirable to obtain the benefits given by both mechanical and chemical fixing of the fibers, for which a mixture of different fibers is introduced into the composition.

H. Continuous fibers
The terms “filaments”, “continuous filaments” or “continuous fibers” as used in the present patent specification and the attached patent claims include individual continuous filaments or continuous strands consisting of discontinuous or continuous fibers that are introduced into a hydraulically settable mixture during extrusion. Continuous fibers should be distinguished from discontinuous or chopped fibers, which are mixed in a hydraulically settable mixture and usually have an arbitrary orientation (although a certain orientation of the fibers can occur as a result of the extrusion process).

 When laying continuous fibers in a hydraulically settable mixture, their fixing is carried out over a significantly longer length than in the case of discontinuous fibers, and such fibers give the final cured article substantially different characteristics than short fibers. Continuous fibers laid in a hydraulically settable mixture significantly increase the tensile, bend and tear strength of the cured hydraulically settable product under the influence of internal or external pressure, depending on the orientation of the fibers. Continuous fibers placed in a hydraulically settable structural matrix also typically increase the toughness and elongation of the hydraulically settable product. Preferred fibers have sufficient tensile and shear strength, which ensures their independent contribution to the strength of the product.

 The effect of "pulling out" in the case of continuous fibers, as a rule, is minimized, since the fibers are fixed over a large length of the product, which complicates their mixing. As a result of the minimal pull-out effect, the difference between the chemical and mechanical fixing of the fibers will be less significant than in the case of intermittent fibers.

 Continuous fibers of any type, including inorganic and organic fibers, can be introduced into the hydraulically settable mixture, and the width or thickness of these fibers can correspond to the required strength, length, thickness or other characteristics of the extruded product. Continuous fibers can be stacked in a hydraulically settable matrix in the form of individual fibers, or as a continuous bundle of continuous or discontinuous fibers. You can accept any bundles of fibers, including ordinary bundles in the form of "strands", that is, groups of unwoven fibers, "yarn", which is a group of interwoven fibers, "rovings", which is a group of bundles of fibers, consisting of unwoven strands or interwoven yarn tow, representing a bunch of unwoven fibers, or "mat", which is a sheet of fibers.

 The number or volume of continuous fibers placed in a hydraulically settable matrix depends on the required characteristics of the final product, and the most important criteria for choosing the volume of continuous fibers introduced into the product are strength, toughness, flexibility and cost. Typically, the volume of continuous fibers in the product will be approximately 0.5% to 30% of the volume of the hydraulically settable structural matrix. A more preferred volume of continuous fibers is from about 1% to 20%. The most preferred volume of continuous fibers is from about 2% to 10%.

 However, it is understood that a very important factor in determining the amount of continuous fibers used is their strength. The greater the tensile strength of the fiber, the smaller the number of these fibers should be added to obtain the same tensile strength of the final product. Of course, while some fibers have a high tensile strength, other types of fibers with a lower tensile strength may be more elastic. Therefore, to obtain a final product with maximization of various characteristics, such as high tensile strength and high elasticity, a combination of two or more continuous fibers may be required.

 In addition, the volume of continuous fibers required to obtain the desired properties of the product depends on the method of laying the continuous fibers in a hydraulically settable structural matrix during extrusion. Such fibers can be laid in a hydraulically settable structural matrix in several different configurations, as well as at different depths from the surface of the product. To obtain an anisotropic product with maximum strength in the direction of extrusion of the fiber can be placed parallel to each other throughout the product along an axis that coincides with the direction of extrusion. The required fiber volume can also be reduced by cross-laying continuous fibers by spiral winding the fibers in opposite directions as the product is extruded. In addition, the fibers can be mixed both in parallel and in a spiral, which allows you to take advantage of both laying methods.

Common types of continuous fibers used in the present invention include fiberglass, polyaramide fibers, graphite fibers, carbon fibers, polyethylene fibers and other organic fibers. Fiberglass is often used because of its low cost, dimensional stability, high impact resistance, moderate strength values and modulus of elasticity and ease of handling. Polyaramid fibers, commonly referred to as Kevlar (Kevlar ^®), have very high specific strength and elastic modulus, but relatively low shear strength and compression. Polyaramide fibers are often used in vessels operating under pressure, since they are not exposed to shear and compression stresses. The largest range of required values of strength and elastic modulus can be achieved using graphite fibers, which can be developed to provide most of the required parameters (although this may be associated with an increase in cost). The above continuous fibers can be purchased from companies such as Hercules Aerospace Co., Magna, Utah: 3-M, St. Paul, Minnesota: Owens-Corning Fiberglass, Toledo, Ohio: Pittsburg Plate Glass , Manville Co .: Vetrotex St. Gobain; DuPont; Allied Fibers and Amoco.

 Alternatively, continuous fibers can be made from natural organic fibers such as cotton, hemp and jute. Although such fibers have a relatively low tensile strength, they are much cheaper than glass, polyaramide or graphite fibers. Natural organic fibers can be more economical in the manufacture of products that are not subjected to high stresses.

1. Dispersants
The term “dispersants” is used here to define the class of materials that can be added to reduce the amount of water introduced while maintaining the same flow characteristics. Dispersants typically provide a reduction in viscosity and yield strength of a hydraulically settable mixture. A more detailed description of the use of dispersants can be found in the master's thesis: Andersen, PJ, “The Effect of Organic Superplasticizing Additives and Their Components on the Zeta Potential and Similar Characteristics of Cement Materials” (1987). For purposes of information disclosure, the above dissertation is incorporated herein by reference.

 Dispersants typically function by adsorption into the surface of the particles of a hydraulically settable binder and / or into an adjacent double colloidal layer between the binder particles. This creates a negative charge on the surfaces of the particles, which leads to their mutual repulsion. This repulsion of particles contributes to "lubrication" by reducing the "friction" or attractive forces, which otherwise could increase the interaction between the particles. Due to this, it is possible to reduce the volume of water introduced into the initial mixture, while maintaining the workability of the hydraulically settable mixture.

 A significant decrease in viscosity and yield strength may be desirable in cases where ductility, cohesion and / or form resistance are less important or when it is desirable to reduce the initial concentration of water. The introduction of the dispersant helps to maintain the workability of the hydraulically settable mixture even in the case of adding a very small amount of water, especially in the case of “water shortage”. Therefore, the addition of dispersant provides the possibility of further increasing the degree of water deficiency, although extruded products can sometimes have slightly reduced form stability if too much dispersant is used. However, reducing the amount of water introduced at the initial stage theoretically leads to an increase in the strength of the final cured article according to the strength equation.

The presence or absence of water deficiency is determined by both the stoichiometric volume of water required for hydration of the binder and the volume of water necessary to fill the pores between the particles in the hydraulically settable composition
mixtures, including particles of the hydraulically settable binder itself, particles of aggregate material and / or fiber. As mentioned above, improved particle packaging reduces the pore volume between the hydraulic binder and the aggregate particles and, therefore, the amount of water required to completely hydrate the binder and to maintain the ductility of the hydraulically settable mixture by filling the pores between the particles.

However, due to the nature of the dispersant coating mechanism, often the order in which the dispersant is introduced into the mixture is critical. If a reagent that causes flocculation and gelation, such as Tylose ^® or starch, is added, the dispersant must be added first, followed by the flocculating reagent. Otherwise, the adsorption of the dispersant by the surface of the particles of the hydraulic binder will be difficult, since the Tylose ^® reagent or starch will be irreversibly adsorbed and forms a protective colloidal layer on the surface that prevents the adsorption of the dispersant.

 A preferred dispersant is a sulfonated naphthalene-formaldehyde condensate, an example of which is WRDA 19 sold by W.R. Grace, Inc., Baltimore, USA. Other dispersants that will work well include a sulfonated condensate of melamine-formaldehyde, lignosulfonate and polyacrylic acid. The sodium salt of the sulfonated condensate of melamine-formaldehyde can be introduced after hydraulic cement, by reacting with water, has time to form primary hydration products (such as etgringite), which will increase the specific surface area of the cement particles and provide improved particle dispersion.

 Another way to improve the fluidity of a hydraulically settable mixture at low pressure is to add other reactive materials with a high specific surface area, such as silica fume. These materials also increase the yield strength and, therefore, the dimensional stability of the extrudable product.

 The amount of dispersant added is usually up to about 5% by weight of the hydraulically settable binder, more preferably in the range of about 0.25 to 4%, and most preferably in the range of about 0.5 to 2%. However, it is important to prevent the addition of an excessive amount of dispersant, as this may slow down hydration reactions, for example, between hydraulic cement and water. The addition of an excessive amount of dispersant can practically impede hydration, thereby completely terminating the binding effect of the hydraulic paste.

 Dispersants contemplated by the present invention are sometimes referred to in the concrete industry as “superplasticizers,” “reagents to reduce water content,” or “potent reagents to reduce water content.” In order to better distinguish between dispersants and reagents for modifying rheological characteristics, which often play the role of plasticizers, the term “superplasticizer” is not used in the present patent description.

J. Set accelerators
In some cases, it may be desirable to accelerate the initial setting of the hydraulically settable mixture and to ensure the accelerated attainment of form stability of the extrudable product by introducing an appropriate setting accelerator. Such materials include Na ₂ CO ₃ , KCO ₃ , KOH, NaOH, CaCl ₂ , CO ₂ , triethanolamine, aluminates and inorganic alkaline salts of strong acids such as HCl, HNO ₃ and H ₂ SO ₄ . Almost any composition that increases the solubility of gypsum and calcium hydroxide will help accelerate the initial setting of hydraulically set mixtures, especially cement mixtures.

 The amount of setting accelerator added to a particular hydraulically settable mixture will depend on the degree of setting acceleration required. This in turn depends on a number of factors, including the composition of the mixture, the time interval between the stages of mixing the components and the formation or extrusion of a hydraulically settable mixture, the temperature of the mixture and the type of accelerator. One skilled in the art will be able to adjust the amount of setting accelerator in accordance with the parameters of a particular process to optimize the setting time of the hydraulically settable mixture.

K. Coatings
The present invention provides for the possibility of coating extrudable hydraulically settable products with sealing materials, paints and other protective coatings. Possible coatings include calcium carbonate, melamine, polyvinyl chloride, polyvinyl alcohol, polyacrylate, hydroxypropyl methylcellulose, polyethylene glycol, acrylics, polyurethane, polyethylene, synthetic polymers, polylactic acid, Biopol ^® (polyhydroxybutyrate and hydroxyvalerate copolymer), paraffins ( or petroleum paraffin), elastomers, kaolin clay, polyacrylates and synthetic polymers (including biodegradable polymers). Biopol ^{® is} manufactured by ICI in the UK.

 For example, a particularly useful coating is an acid-resistant coating consisting of sodium silicate soluble in water (pH 7.0). Resistance to acids is important, for example, in cases where the extruded pipe is used, for example, to transport aqueous solutions of acids. If it is desired to protect the extruded product from alkaline substances, it can be coated with a suitable polymer or wax that is used to coat paper or paperboard products. If the extruded product is intended to be in contact with food, it is preferable to use a material approved by the U.S. Medicines and Food Administration for use as a coating.

 Coatings can be applied to extruded products using any coating methods known in the art. The coating can be applied by spraying any of the above materials onto the surface of the extruded product or by immersing the product in a bath containing the appropriate coating material. If the coating material is applied to the surface of a flat or curved product by spraying, then it can be distributed or smoothed with a straight or shaped squeegee, held at a certain distance from the product or moved directly along its surface. In addition, coatings can be extruded together with the extruded product to combine the coating process with the extrusion process.

II. Extrusion of hydraulically settable mixtures
The main structural component of the extrudable products of the present invention is a hydraulically settable structural matrix formed by the reaction products of a hydraulically settable mixture and water. Inside the base structural matrix, there are other components (such as fibers, fillers, reagents for modifying the rheological characteristics, dispersants and setting accelerators) that give the products additional characteristics and properties. Using the method of microstructural engineering and material technology, these various ingredients in various concentrations and proportions can be included in the mixture to give the mixture the required characteristics of form stability and final strength, impact strength and other operational characteristics necessary for the final cured product.

 The following are the main stages of the process of extrusion of a hydraulically settable mixture: (1) selection of the required properties and attributes of the product to be extruded from a hydraulically settable mixture, including its dimensions and strength characteristics; (2) selection of the required parameters of the respective extrusion process, including the type of extruder, the shape of the die plate, as well as pressure, speed and temperature; (3) determination of the optimal composition and rheological parameters or the range of rheological parameters of the corresponding hydraulically settable mixture, designed to provide the required properties and attributes of the product, as well as the required parameters of the extrusion process; (4) preparing an appropriate hydraulically settable mixture having the desired composition and rheological characteristics; (5) extrusion of a hydraulically settable mixture in order to obtain the desired products or blanks (semi-finished products) that will subsequently be shaped into the desired products; and (6) curing the product after extrusion or subsequent processing to obtain the final cured product. The curing process, if desired, can be accelerated, for example, by autoclaving or by holding the partially cured product in a high humidity environment.

A. Giving the product the required characteristics
Using the compositions and methods described herein, it is possible to mass-produce a wide range of products by extruding a hydraulically settable mixture to give it the desired shape of the product or workpiece, which will subsequently be shaped into the desired product. Products molded using the extrusion methods of the present invention are characterized by high compressive, tensile and bending strengths, as well as high packing densities of particles of solid aggregate material and a hydraulically settable mixture. The result is a hydraulically settable material with a higher density and lower porosity than materials made by known methods. Due to this, the product has a low permeability and provides a low degree of moisture diffusion. These characteristics are made possible through the use of microstructural engineering, which allows you to pre-design the required characteristics and operational properties of the material.

 The high packing density of particles in extruded products is determined by: (1) the choice of aggregate particles with a certain size distribution and shape, which allows you to optimize the natural packing density of the particles, and (2) extrusion of a hydraulically set material, carried out in general at high pressure, which provides an even higher packing density of particles in excess of the natural packing density, especially in cases where the initial mixture had a water shortage.

 The high packing density of particles and the low ratio of the volumes of water and hydraulically settable mixture, due to the low initial water content, make it possible to obtain extruded products with very low porosity and, therefore, with high strength (in accordance with the strength equation). The use of dispersants makes it possible to further reduce the initial concentration of water in order to obtain a hydraulically settable mixture with an increased water deficiency, which nevertheless can be extruded under pressure.

 The type of aggregate used will largely depend on the required strength and density values of the final cured article, as well as the required cost. Aggregates such as crushed sand, crushed granite, crushed basalt, silica, gypsum and clay are very cheap and can provide a significant reduction in the cost of manufacturing extrudable products containing these materials. These aggregates are also characterized by high density and high compressive strength.

 The inclusion of a hydraulically settable binder, such as gray or white Portland cement, will generally provide a waterproof article that resists the ingress of water and other liquids. However, other hydraulically settable binders, such as gypsum hemihydrate, are less water resistant and provide products with less water resistance. If it is desired to obtain a product with increased water resistance, it may be preferable to apply a suitable coating to the surface of the extruded product.

 The inclusion of chopped and continuous fibers and other high-strength fillers can provide a significant increase in tensile, bending and tensile strength of the final cured products. Depending on the oriented or arbitrary laying of the fibers in the hydraulically settable matrix, and also depending on the parallel or spiral laying of the fibers, it is possible to provide increased strength in one direction or equal strength in all directions. During the extrusion process, the fibers are usually oriented to some extent in the direction of extrusion.

 Various short and continuous fibers have different characteristics of tensile strength and under pressure, flexibility, tensile strength, elongation to break and stiffness. The type of fibers included in the hydraulically settable material depends on the desired product characteristics. In order to provide a positive combination of characteristics of fibers of various types, in some cases it is preferable to supply hydraulically settable material with fibers of two or more types.

 In view of the foregoing, cured extruded articles will preferably have a tensile strength in excess of about 15 MPa. In many cases, depending on the composition of the mixture, the concentration of water and the pressure of extrusion, it is possible to obtain extruded products with tensile strength of not less than about 30 MPa, and in some cases up to about 50 MPa or more. Due to the ability to remove a significant proportion of the intermediate voids that are commonly found in most cement products, the cured extruded hydraulically set materials of the present invention can have a tensile and compressive strength ratio of about 1: 7, which is better than conventional concrete products in which the ratio of tensile and compression strength is usually only about 1: 10. In addition, in the case of high strength fibers in sufficient concentration, the present invention eniyu it becomes possible to obtain a hydraulically settable materials with a ratio of tensile strength and compression, reaching approximately 1: 3.

Due to the possibility of extrusion of relatively thin-walled objects with relatively large internal cavities, it is possible to produce extrusion products with a relatively low bulk density. The bulk density of the extruded products with a multicellular structure will preferably be less than about 1.5 g / cm ³ . Due to the possibility of extrusion of multicellular objects, in which the ratio of wall thickness to volume of cavities will be significantly lower than that provided by known methods, it is possible to extrude products with a bulk density not exceeding about 0.7 g / cm ³ and, in some cases, about 0, 3 g / cm ³ . The low, medium or high bulk density of the extruded product generally depends on the required performance characteristics for a given application, as well as on the ratio of the volumes of solid walls and internal cavities of the product. The specific gravity of the solid walls of the products will usually be in the range indicated in the present description.

In view of the foregoing, extruded products of the present invention will typically have a significantly higher ratio of tensile strength and bulk density than cement products made by known methods. Preferably, the extruded products will have a ratio of tensile strength and bulk density in excess of about 5 MPa-cm ³ / g, more preferably in excess of about 15 MPa-cm ³ / g, and most preferably in excess of about 30 MPa-cm ³ / g .

B. Selection of the extrusion process
The choice of the type of extrusion process to be used will depend on the nature of the hydraulically settable mixture to be extruded, as well as the required characteristics of the extruded product. Although the compositions of the hydraulically settable mixtures of the present invention are characterized by carefully selected rheology and ductility parameters, which makes them suitable for other shaping processes, the most important property of the products of the present invention is the possibility of continuous extrusion to obtain extruded products that acquire shape stability immediately after the extrusion process or in a very short time after that. The continuous nature of the extrusion process enables economical and cheap manufacturing of a wide variety of products.

 As mentioned above, the combination of particle packing density, water deficiency and compaction during the extrusion process allows you to create a hydraulically settable mixture with discrete rheological parameters. An important criterion for the extrusion process is the choice of the extruder, designed to create the required pressure or various pressures in the desired range in accordance with the specific composition of the mixture. Maintaining pressure in the required range is necessary to increase the packing density of particles and at the same time reduce the volume of intermediate voids, which reduces the effective value of the water deficit in the mixture. This provides improved lubrication of the particles and improves the ductility and fluidity of the mixture.

 The best characteristics of the product, as a rule, are ensured by applying a pressure that corresponds to the packing density of the particles, water deficiency and particle strength of the aggregate material inside the mixture. Low pressure may not be sufficient to give the hydraulically settable mixture the required fluidity. Conversely, an increased pressure can lead to crushing of some particles of the aggregate material in a hydraulically settable mixture and to the compaction of the mixture to such an extent that excess water forms in it. Excess water in some cases can lead to a decrease in the viscosity and / or yield strength of a hydraulically settable mixture to such an extent that the mixture does not acquire sufficient shape stability.

 Depending on the required pressure and the required shear forces, which must act on the hydraulically settable mixture, either a piston or a screw extruder can be adopted. The advantage of a piston extruder is the possibility of applying a higher pressure. If you need to use particularly high pressure, up to 100,000 psi, a piston extruder is currently the only option.

 Screw extruders usually cannot develop as high a pressure as piston extruders, and they are preferably used in cases where a particularly high pressure is not required. An advantage of screw extruders is the creation of internal shear stresses that occur when the screw rotates, as well as the possibility of creating a vacuum or vacuum in the extruder chamber, where the hydraulically settable mixture is located, which allows more continuous removal of unnecessary air from the mixture. A twin-screw extruder, commonly used for experimental purposes, is equipped with two parallel screws, which makes it possible to use a wider die and increase the extrusion pressure. In most other aspects, a twin screw extruder is similar to a single screw extruder.

 However, when using hydraulically settable mixtures with a particularly high degree of water deficiency, it is often necessary to use a piston extruder to expose the mixture to the high pressure required to ensure fluidity. In such cases, the hydraulically settable mixture may look like dry granular material prepared by mixing the components in a drum. The granules are placed in the chamber of the piston extruder, where a vacuum (vacuum) is created, and then compressed under the action of high pressure developed by the piston, which allows the extrusion of the material. The use of a two-chamber piston extruder provides the possibility of a semi-continuous extrusion process.

 Currently, the preferred method for large-scale mixing and extrusion processes under industrial conditions is the use of equipment in which the materials included in the hydraulically settable mixture are automatically and continuously metered, mixed, deaerated and extruded using a single screw or twin screw extrusion apparatus. Both single screw and twin screw extrusion apparatus are equipped with special purpose sections for mixing with low shear, mixing with high shear, evacuating and pumping. Single screw or twin screw extrusion apparatus is equipped with screws with different pitch and orientation of the blades, which allows you to perform the required operations in each of the sections.

The main types of extruders include extruders for clay, plastic, or food. The clay extruder is usually equipped with a screw with a very small pitch and a large height of the blades, and the angle of inclination of the blades near the die can reach 90 ^o . A small step provides an increase in the contact area between the auger blades and the extrudable material. The reduction in pitch and the ensured increase in the contact area can increase the pressure and shear force developed by the extruder.

 On the other hand, extruders for plastics or food products have a significantly larger pitch and lower blade height than a clay extruder. In this case, the pressure and shear force are controlled by increasing or decreasing the rotational speed of the screw of the extruder. Of course, increasing the rotational speed of the screw of the extruder for clay also leads to an increase in pressure and shear forces.

C. Development of a hydraulically settable mixture
The two main criteria used to determine the desired composition of a hydraulically settable mixture are to provide the desired rheological characteristics before, during and after the extrusion process, as well as to provide the desired characteristics of the final cured extruded product. As indicated above, the rheological characteristics of the hydraulically settable mixture are preferably selected so that the mixture can flow and undergo extrusion under the conditions used in the extrusion process, and so that after completion of the extrusion the mixture acquires shape stability immediately or in the shortest possible time.

1. The choice of rheological characteristics of the mixture
As described above, the initial rheological characteristics of the mixture can be set by adjusting: (1) the packing density of the aggregate particles and the hydraulically settable mixture, (2) the volume of water, including the degree of water deficiency, and (3) the types and concentrations of any organic polymer reagents for modification rheological characteristics, plasticizers or dispersants. The relationship of these materials and conditions was discussed in detail above.

 In addition, the rheological characteristics of a hydraulically settable mixture can be changed by applying shear forces to provide a shear thinning effect or pseudo-plastic behavior of a water-deficient mixture, or by compressive forces that reduce the degree of water deficiency by compressing aggregate particles and a hydraulically settable binder to each other. In view of the foregoing, the degree of water deficiency should correspond to the compressive and shear forces acting on the hydraulically settable mixture. Thus, in the General case, the increase in compression and shear forces associated with the extrusion process, allows to reduce the amount of water introduced into the initial mixture.

 The termination of the compression and shear forces after extrusion of the hydraulically settable mixture and shaping it to the desired product results in a form-resistant product, the particles of which are held together under the action of internal adhesion of capillary water and surface tension. However, these internal forces depend on the volume of water in the capillaries of the material of the extruded product. If water is insufficient, then capillary forces will be insufficient to ensure adequate cohesion. Conversely, with an excess volume of water, the yield strength of the material will be insufficient to maintain shape stability. The volume of residual water depends on the initial volume of water and on the degree of compression during the extrusion process.

 After hydration, the extruded hydraulically settable material will gain final strength characteristics. The compressive strength of the material, determined by the equation of strength, primarily depends on the porosity of the finally cured material. The same applies to a certain extent to the tensile and bending strength of the cured material. Porosity can be reduced by increasing the initial packing density of the particles, as well as by reducing the initial concentration of water (i.e., increasing the degree of water deficiency). The desired level of compressive strength will depend on the specific performance of the desired product.

 In addition, the compressive strength can be increased by using a stronger aggregate. Conversely, if it is desired to obtain a less durable but lighter product, then lightweight aggregates can be used. Tensile and bending strength can be changed by changing the concentration of fibers. Shorter and stronger fibers, such as ceramic fibers, tend to produce relatively stiff final cured products with high tensile and bending strength. Other fibers, for example, cellulose, have lower tensile strength, but are cheaper and can be adequately used in cases where the characteristics of flexibility and toughness are more important.

a. Particle Density Optimization
Providing optimized packing of solid particles in a hydraulically settable mixture is required to give this mixture the desired rheological and ultimate strength characteristics. After determining the packing density of the particles of the dry mixture, you can calculate the amount of water that should be introduced into the mixture to ensure the required degree of water deficiency. A detailed description of the theory, models, and steps necessary to accurately and reproducibly optimize the packing density of solid particles in a hydraulically settable mixture is given in parallel patent application of the United States of America No. 08/109100, filed August 18, 1993 addressed to Dr. Per Just Andersen and Simon K. Hodson entitled "Structurally Optimized Compositions and Processes for Microstructural Engineering Cement Blends." For purposes of information disclosure, this application is incorporated herein by reference. In addition, the mathematical and graphical models used to determine and calculate the packing density of the mixture particles are given in Johansen, V. and Andersen, PJ, “Particle Packaging and Concrete Properties”. Materials Science of Concrete II, pp. 118-122, American Society of Ceramics (1991). For purposes of information disclosure, this article is incorporated herein by reference.

 To ensure the required packing density of various particles within a hydraulically settable matrix, including particles of a hydraulically settable binder and aggregates, it is necessary to use particles of at least two size ranges. To increase the packing density of particles to a higher theoretical limit, in some cases it may be preferable to use particles of three or more size ranges. From the point of view of particle packing, mixtures with particles of two different size ranges are called "two-component systems", mixtures with particles of three different size ranges are called "three-component systems", etc. For simplicity, two components of a two-component system can be called fine-grained and coarse-grained components, and three component of the three-component system - fine-grained (or fine-grained), medium-grained and coarse-grained components.

 To achieve an optimal level of particle packing, it is preferable that the average particle size of one size range exceed the particle size of the next smaller size range by at least seven and a half times, preferably ten times, and most preferably twelve and a half times. (In many cases, this ratio may be higher). For example, in a two-component system, it is preferable that the average particle size of the coarse-grained component is at least seven and a half times the average particle size of the fine-grained component. Similarly, in a three-component system, it is preferable that the average particle size of the coarse-grained component is at least seven and a half times greater than the average particle size of the medium-grained component, and the average particle size of this component should preferably be at least seven and a half times greater than the average particle size fine-grained component. However, by adding particles of different sizes, the need for such a high ratio between the sizes of particles of different grain sizes can be avoided.

 In a three-component system, it is preferable that the diameter of the fine-grained aggregate particles is from about 0.01 μm to 2 μm, the average particle diameter is from about 1 to 20 μm, and the particle size of the coarse aggregate is from about 100 μm to 2 mm. In a two-component system, any two of the size ranges from the above may be used. Depending on the number of different types of particles, particles of larger and smaller diameters, as well as particles from various size ranges, can be used.

 The term "type" as used in the present description and the attached patent claims in relation to aggregate, hydraulically settable binder and other solid particles, refers to both the nature of the material used and the particle size ranges. For example, although the particle diameter of the coarse aggregate is typically from about 100 μm to 2 mm, one type of coarse aggregate may have particles from about 200 to 500 μm, while the particles of another type can have sizes from about 700 μm to 1.2 mm . As indicated in the present description, the optimal packing of particles in the mixture can be achieved through the selective combination of various types of aggregates. Each type of aggregate is made up of particles of a certain average size; however, studies have shown that the use of particles with intermittent gradation provides good packaging, but reduced ductility during molding compared to continuous gradation.

 In general, a two-component (or binary) packaging system rarely provides an overall packing density of over 80%, while the upper limit for three-component (or triple) systems exceeds 90%. In most cases, to increase the degree of particle packing, it is necessary to introduce at least four components, although expanding the size range and increasing the optimization of particle sizes of two- or three-component systems can provide an increase in the degree of packing beyond 80% and 90%, respectively.

 As the hydraulically settable binder of the present invention, hydraulic cement, gypsum, or calcium oxide, and in some cases ash or silica microparticles, are typically used. Hydraulic cement is characterized by hydration products resulting from a reaction with water. The particle sizes of hydraulic cement are usually from 0.1 μm to 100 μm. The average particle size of Portland cement type 1 is from about 10 to 25 microns.

 The various types of aggregates and hydraulically settable binders used in the present invention are further characterized by an average diameter (d ') and a natural packing density φ of various types of particles. These values are determined experimentally and are used to calculate the packing density of the resulting hydraulically settable mixture.

где W_м = вес материала,
SG_м = удельный вес материала,
V_м = объем материала.The natural packing density of each type of material is determined by filling the material into a cylinder whose diameter is at least ten times the diameter of the largest material particle. Then the cylinder is tapped on a hard surface until the material is completely compacted. After measuring the height of the material in the cylinder and the weight of the material, the packing density is determined by the following formula:

where W _m = weight of material
SG _m = specific gravity of the material,
V _m = volume of material.

 Of course, two or more hydraulically settable binders of various types can be added to the mixture. However, the particle sizes of the hydraulically settable binders are usually so small that the combination of different types of hydraulically settable binders does not significantly affect the packing density of the mixture. However, in some situations, a combination of hydraulically settable binders of various types may be appropriate. In such situations, hydraulically settable binders of various types can be presented in the form of pseudoparticles in the same way as is practiced for fine-grained and coarse aggregate.

 The above process is a method for determining the packing density for all possible combinations of a given raw material. From the point of view of the rheological effect, an increase in the density of the packing of particles makes it possible to reduce the water content while maintaining the same level of plasticity and the suitability of the mixture for molding, i.e., workability. In addition to improving the rheological characteristics of the mixture in the wet state, maximizing the packing density of the particles also increases the strength of the final cured product by reducing the volume of space between the particles filled with air or water, or a combination of them (in accordance with the strength equation).

 However, it should be understood that the "optimization" of the particle packing system is not necessarily achieved by simply maximizing the particle packing density. Typically, maximizing particle packing density improves the desired performance achieved by particle packing. However, restrictions such as the cost and / or availability of any particular aggregates may justify the use of less dense particle packing, but still allow you to get a mixture with adequate rheological characteristics for this purpose.

 Although it was previously recognized that increasing the packing density of particles helps to control the rheological characteristics of a hydraulically settable mixture, the maximum packing density in known products did not exceed about 65%. In contrast, thanks to the above-described particle packing methods, it is possible to provide values of the natural particle packing density in excess of 65% and even reaching 99%.

 Typically, the particle packing density should be in the range of about 0.65 to 0.99, more preferably in the range of about 0.70 to 0.95, and most preferably in the range of about 0.75 to 0.90 . (The increase in costs required to achieve a 99 percent particle packing density often makes this method economically unfeasible, so the most preferred packing density will be slightly lower).

 In FIG. 1, illustrating the concept of particle packing, shows a cross section of a material with effective particle packing (particle packing density is 0.70). In FIG. 1, it can be seen that the space between the large aggregate particles, which is usually filled with air, is instead occupied by the small aggregate particles. In addition, the space between large and small aggregate particles, which is also usually filled with air, is in turn occupied by even smaller aggregate particles. Thus, the volume of air between the particles is significantly reduced, and the packing density of the particles increases significantly.

 In FIG. 2, which gives a graphical illustration and quantitative data on the actual packing density of particles, it is shown that in a typical packing system (with a packing density of particles 0.70), the total volume of the mixture consists of solid particles (70%) and air in the spaces between them (30 %). It is in this intermediate space that water is introduced to lubricate the individual particles, which provides adequate flow characteristics and ductility of the hydraulically settable mixture, especially when the packing density is temporarily increased due to the extrusion of the mixture at elevated pressure.

b. Water shortage
As indicated above, the volume of water introduced into any given hydraulically settable mixture should be metered carefully to provide the required workability and rheology characteristics. However, it should be understood that the volume of water introduced into any given mixture is often not determined by the volume or even the mass of the dry hydraulically settable mixture, but is directly related to the packing density, more specifically, to the volume of intermediate voids in the mixture.

 To clarify this conclusion, refer to FIG. 3A and 3B, where two systems with different particle packaging are shown having the same volume and zero degree of water deficiency. This means that exactly such a volume of water is introduced into the mixture that ensures filling all the gaps between the particles. Both mixtures shown have similar rheological characteristics, despite a significantly different concentration of water. As graphically shown in FIG. 3A and 3B, a mixture in which a particle packing density of 0.65 (FIG. 3A) contains seven times more filling water than a mixture with a particle packing density of 0.95 (FIG. 3B). (Of course, it can also be predicted that a mixture with a higher packing density will also have higher strength after curing according to the strength equation).

 In FIG. 4 shows an optimized particle packing system in which the water deficit is 50%, i.e. only half of the space between the particles is filled with water (50% of the space, or 15% of the total volume of the mixture). For comparison, it can be pointed out that two hydraulically settable mixtures with the same total volume and the same volume of water will have a different degree of water deficiency if the packing density of particles in these systems is different. The lower the packing density of the particles, the greater the water shortage, since this increases the amount of space between the particles that needs to be filled.

 In FIG. 5 is an illustration and a graph showing that applying pressure to a hydraulically settable mixture (for example, in an extruder) presses particles against each other, which in turn leads to an increase in particle packing density. Since particles and water are practically incompressible, the volume of intermediate voids is significantly reduced, while the volume of water that can be used to lubricate the particles is clearly increasing. Although the air is easily compressible and will not substantially impede the compression process described above, it is nevertheless preferable to remove the air by creating a vacuum to prevent the back expansion of the air after the termination of the compressive forces.

 The exact amount of water that should be added to any given hydraulically settable mixture must be carefully calculated before the actual water enters the mixture, and also checked after that. As indicated above, a hydraulically settable binder does not necessarily react with all of the theoretical stoichiometric volume of water required to completely hydrate the binder. Instead, part of the water will occupy the intermediate voids, at least for a while, until this water reacts with a hydraulically settable binder.

 Of course, it should be borne in mind that the degree of water deficiency is not the only factor determining the rheological characteristics of a hydraulically settable mixture. Other additives, such as dispersants and reagents for modifying rheological characteristics, significantly affect the viscosity, workability and other rheological characteristics of the mixture. A person skilled in the art will be able to adjust the degree of water deficiency with the addition of a dispersant and / or reagent to modify the rheological characteristics to obtain a hydraulically settable mixture having the desired characteristics.

D. Preparation of hydraulically settable mixture
As mentioned above, any mixing means suitable for a particular production process will ensure good particle packing, but it is believed that the maximum particle packing density is achieved if the aggregate particles and the hydraulically settable mixture are mixed before water is added. After reaching a state of readiness to add the required volume of water, any suitable mixing process may be used. To obtain a mixture with a particularly homogeneous composition, agents can be used that create high shear stresses in a hydraulically settable mixture, such as high shear mixers, which are described in more detail below. If a lower shear is required, then a dough mixer or a clay mill can be used. Finally, the materials can be mixed and extruded simultaneously using a single screw or twin screw extruder. In combination with any mixing process, high-frequency vibration can be used to aid mixing of the components.

 Currently, the preferred method for preparing the appropriate moldable mixture in an industrial environment is the use of equipment in which the materials introduced into the molding mixture are subject to automatic and continuous dosing, mixing in a mixer (or clay grinder), deaeration and extrusion using a screw extrusion press. You can also pre-mix the components in a vessel in the required proportions and then pump the pre-mixed components into a mixing or kneading unit.

 A preferred type of mixer is a twin-shaft kneading type mixer with sigmoid-shaped blades equipped with an extrusion screw. This mixer has an adjustable speed and, therefore, can be configured for different shear forces for different components. Typically, the molding sand is mixed for no more than 60 minutes and then extruded from the mixer by extrusion.

 In certain circumstances, it is desirable to mix certain components in a high shear mixer, resulting in a well dispersed and uniform mixture. For example, some blending may be required for some fibers in order to completely destroy agglomerates or tear the fibers apart. High shear mixing results in more uniform mixing of the mixture, which improves the consistency of the uncured molding mixture and also increases the strength of the final cured sheet. This is due to the fact that mixing with high shear provides a more uniform dispersion of the fibers of the particles of filler materials and a binder in the composition of the mixture, thereby creating a more uniform structural matrix in the cured sheets.

 High shear mixers used to produce high uniformity blends as described above are the subject of the invention and are described in US Pat. No. 4,225,247 "Mixing and Stirring Device"; US patent N 4552463 "Method and apparatus for the preparation of colloidal solutions"; US patent N 4889428 "Rotary mill"; US patent N 4944595 "Apparatus for the manufacture of cement building materials" and US patent N 5061319 "Method for the manufacture of cement building materials." For the purposes of disclosure, the above patents are incorporated herein by reference. The high shear mixers used within these patents are available from E. Khashoggi Industries in Santa Barbara, California, which is the assignee of the present invention.

 Different mixers transfer different shear forces to the moldable mixture. For example, a clay mixer conveys a greater shear force than a conventional concrete mixer, but less force than an intensive Eirich mixer or twin-screw extruder for food.

 However, it should be borne in mind that high speed shear mixers should not be used for materials that have a relatively low viscosity. In cases where a more cohesive and ductile mixture is desired, it may be desirable to mix some components, including water, in a high shear mixer, and then increase the concentration of solid components such as fibers and filler materials using a low kneading unit shear force.

 In some cases, the order of preparation of the mixture affects the characteristics of the hydraulically settable mixture. In the presently preferred embodiment of the present invention, in which both the dispersant and the reagent are used to modify the rheological characteristics, it is preferable to first mix the hydraulically settable binder with water in a high shear mixer. The dispersant is preferably added after sufficiently wetting the particles of the hydraulically settable mixture. After the dispersant is mainly adsorbed by the particles of the hydraulically settable mixture, a reagent is added to the mixture to modify the rheological characteristics.

E. Extrusion of hydraulically settable products
A properly prepared molding sand is fed to an extrusion plant, such as a screw extruder, a piston extruder, or a twin screw extruder, and is extruded. Although the compositions of the hydraulically settable mixtures of the present invention are characterized by carefully selected rheology and ductility parameters, which makes them suitable for other shaping processes, the most important property of the products of the present invention is the possibility of continuous extrusion. It is the continuous nature of the extrusion process that provides the opportunity for economical and cheap manufacturing of a wide variety of products.

 As mentioned above, the combination of particle packing density, water deficiency and compaction during the extrusion process allows you to create a hydraulically settable mixture with discrete rheological parameters. Therefore, an important criterion for the extrusion process is the choice of the extruder, designed to create a carefully calculated pressure corresponding to this particular mixture composition. This is because the compressive force of the extruder provides a temporary increase in the packing density of particles and a simultaneous decrease in the volume of intermediate voids, which reduces the effective value of the water deficit in the mixture. This provides an immediate improvement in particle lubrication and improves the ductility and fluidity of the mixture.

However, the best performance, as a rule, is ensured by applying a pressure that corresponds to the packing density of the particles, water shortage and particle strength of the aggregate material inside the mixture. Low pressure may not be sufficient to give the hydraulically settable mixture the desired fluidity. Conversely, excessive pressure can lead to
various problems, including the crushing of some particles of the filler material in a hydraulically settable mixture, the possible intermittent ejection of the extrudable material from the extruder die instead of continuous extrusion, and the uneven flow through the die.

 Depending on the required pressure and the required shear forces, which must act on the hydraulically settable mixture, either a piston or a screw extruder can be adopted. A screw extruder (Fig. 6) has several advantages, even though it cannot be used for extrusion with such a high pressure as is possible with a piston extruder. These advantages include the creation of constant internal shear stresses that occur during the rotation of the screw, as well as the simplification of the creation of constant vacuum or vacuum conditions in the chamber of the screw extruder to remove any unnecessary air from the hydraulically settable mixture. In some cases, to simplify the process and minimize the number of system components, units are used that are designed for simultaneous mixing and extrusion of the molding mixture. The advantage of the piston extruder shown in FIG. 7, is the possibility of applying a higher pressure. If particularly high pressures are required, up to 100,000 psi, a piston extruder or an extruder with grinding rollers are currently the only options. A piston of a piston extruder and a screw of a screw extruder are only examples of means for applying an extrusion pressure sufficient to ensure the flow of a hydraulically settable mixture and its extrusion through a die; it is clear that other means can be used for this.

 In FIG. 6 shows an enlarged view of a screw extruder 20, which is equipped with a feeder 22, which feeds the molding mixture into the first inner chamber 24 of the extruder 20. In the first inner chamber 24 there is a first screw 26, which exerts pressure on the molding mixture and moves it through the first inner chamber 24 in the direction to the vacuum chamber 28. Typically, the vacuum chamber 28 is under vacuum (vacuum) to remove unwanted air bubbles from the moldable mixture.

 After that, the molding mixture is fed into the second inner chamber 30. The second screw 32 feeds the mixture to the extruder head 34 provided with a transverse slot-like opening (die) 36 with a die width 38 and a die height 39. The cross-section of the slit hole 37 has the shape required for obtain a sheet with the desired width and thickness, the values of which usually correspond to the width of the die 38 and the height of the die 39.

 Alternatively, as shown in FIG. 7, a piston extruder 20 ′ can be used as an extrusion device instead of a screw extruder 10. Instead of a screw 22, a piston 22 ′ is used in the piston extruder to provide a pressure to the mixture and feed it through the first internal chamber 24 ′. The advantage of using a piston extruder is the ability to provide significantly higher pressure on the molding sand. However, due to the high pseudo-plasticity of the mixtures that are usually used according to the present invention, the use of pressures in excess of those that can be developed by a screw extruder, as a rule, is not required and does not give any advantages.

 Currently, the preferred method for large-scale mixing and extrusion processes under industrial conditions is the use of equipment in which the materials included in the hydraulically settable mixture are automatically and continuously dosed, mixed, deaerated and extruded using a twin-screw extrusion apparatus. The twin screw extrusion apparatus is equipped with special purpose sections for mixing with low shear, mixing with high shear, evacuating and pumping. The twin-screw extrusion apparatus is equipped with screws with different pitch and blade orientation, which allows you to perform the required operations in each section.

 It is also possible, as necessary, to mix some of the components in a vessel and pump the pre-mixed components into a twin-screw extrusion unit. In a preferred twin screw extrusion apparatus, screws with the same direction of rotation are used. However, twin screw extrusion machines with counter-rotating augers also perform the same task. For the same purpose, you can also use a clay mill. Equipment meeting these requirements is available from Buhler-Miag, Inc., Minneapolis, Minnesota.

 The pressure applied during extrusion of the moldable mixture is usually determined by the pressure necessary to extrude the mixture through the extruder die, as well as the required extrusion speed. In some cases, the extrusion rate should be carefully controlled so that the speed of molding of the extrusion products matches the speed of subsequent technological operations, such as cutting and / or changing the shape of the extruded product. An important factor affecting the optimal speed or rate of extrusion is the final thickness of the extruded product. A thicker product contains more material, and extrusion must be performed at a higher speed to ensure the formation of the required amount of material. Conversely, a less thick article contains less material, and the extrusion speed required to form the required volume of material may be lower.

 The possibility of catching the molding sand through the die of the extruder, as well as the speed of extrusion, as a rule, are determined by the rheological characteristics of the mixture, as well as the operational parameters and characteristics of the machinery. The rheological characteristics are influenced by such factors as the water content, the hydraulically settable mixture, the reagent for modifying the rheological characteristics and dispersant, the particle packing density, the degree of water absorption and the reaction between the components of the mixture.

 As mentioned above, in order to temporarily increase the workability (plasticity) of the molding mixture if there is a water shortage in the mixture and a certain optimization of the packing density of particles is performed, it is necessary to apply adequate pressure. If there is a shortage of water in the mixture, the space (or spaces) between the particles does not contain enough water to lubricate the particles, which is required to ensure adequate workability under normal conditions. However, when compressing the mixture in an extruder, compressive forces press the particles against each other, thereby reducing the volume of the gaps between the particles and increasing the apparent volume of water available for lubricating the particles. This provides an increase in ductility until the mixture is extruded through the die of the extruder, after which the pressure decreases and the mixture acquires increased stiffness and wet strength almost immediately, which is usually desirable.

 In light of all of the above factors, the pressure acting in the extruder to extrude the moldable mixture should preferably be from about 10 bar to 7000 bar, more preferably from about 20 bar to 3000 bar, and most preferably from about 50 bar to 200 bar.

 It should be noted that extrusion of the molding sand through the die head allows you to orient individual fibers in the molding sand in one direction parallel to the "Y" axis, i.e. in the longitudinal direction of the extruded product.

 As indicated above, it may also be desirable to extrude the hydraulically settable mixture in conjunction with other materials, for example, to provide a layered structure or to obtain an extrusion product that has other materials inside the hydraulically settable matrix. Together with the hydraulically settable mixtures of the present invention, other hydraulically settable mixtures (often having other or complementary properties) can be extruded: fiber mats, coating materials, polymers, clays, graphite (for making pencils), as well as continuous fibers, strips, wire or sheets made from virtually any other material (such as metal). It has been found that, for example, by combining a hydraulically settable sheet and a fiber mat by co-extrusion, the final product has mutually reinforced strength, toughness and other performance characteristics.

F. Accelerated Drying
Although the hydraulically settable materials of the present invention are capable of rapidly acquiring high wet strengths, it may still be desirable to further accelerate the curing or solidification of the extruded materials. This can be achieved through the use of heat to further remove part of the water contained within the hydraulically settable mixture, especially from a surface that requires the highest possible wet strength. Heating is especially desirable if there is excess water in the mixture in order to increase the viscosity and yield strength of the extrudable product and quickly give it shape stability.

 Due to the nature of the extrusion process, it is usually impractical to overheat the extruder die above a certain temperature sufficient to ensure that water is removed during the extrusion process. Overheating of the die can lead to the expansion of the extruded mixture or to the appearance of pockets filled with steam under high pressure, which can lead to an “explosion” of the mixture after extrusion from the die. (However, some heating may be desirable to reduce friction between the extrudable material and the extruder die by forming a steam jacket). Due to the careful regulation of the rheological characteristics of the hydraulically settable mixture and the corresponding heating of the extruder die, it is usually possible to obtain extruded products whose strength is sufficient to perform further operations with them immediately after extrusion.

G. Accelerated setting
In cases where the water deficit in the extruded hydraulically settable mixture is so great that the available water is not sufficient to adequately hydrate the cement or other hydraulically settable binder, it may be preferable to place the extruded article in water or in a high humidity environment. The hygroscopic nature of typical binders, in particular hydraulic cement, leads to the fact that the binder literally absorbs from the air the water that is necessary for hydration. Although this would in any case occur naturally (at least in the case of hydraulic cement), the placement of an extruded product with a high degree of water deficiency in an atmosphere with high humidity significantly accelerates this process of water absorption and also increases the rate of hydration of the binder particles. In particular, in order to substantially increase the strength of the final cured article, autoclaving can be used.

III. Laying continuous fibers during extrusion
The present invention provides devices and methods for the continuous extrusion of a hydraulically settable mixture while simultaneously laying continuous fibers in the mixture to produce new industrial products with a hydraulically settable continuous matrix fiber reinforced matrix. The main goal of incorporating continuous fibers is to increase the elastic modulus, elongation, tensile and bending strength, impact strength and maximum load until the product breaks. The circumferential strength of the product, or tensile strength under the action of internal or external pressure, can also be increased by increasing the angle of laying of the fibers α. These strength characteristics are of particular importance for the functioning of pipes, tanks and all other vessels operating under pressure, in particular thin-walled vessels (in which the ratio of wall thickness to radius is less than 0.1). The fibers can be stacked anywhere in the hydraulically settable structural matrix, including inside the structural matrix and / or on its surface.

 Continuous fibers can be stacked in a hydraulically settable matrix in any desired orientation by introducing fibers into an extruder die (simultaneously with extrusion of a hydraulically settable mixture) by laying the fibers in a hydraulically settable mixture. In this operation, the fibers are “drawn” into the extrudable hydraulically settable mixture. A hydraulically settable mixture envelops the fibers and contracts or compacts as a result of the internal pressure applied to the mixture during extrusion, which minimizes the amount and volume of internal voids or defects within the mixture and maximizes the contact area between the fibers and the hydraulically settable mixture. Increasing the contact area between the fibers and the matrix contributes to a more reliable fixation of the fibers inside the hydraulically settable matrix.

Various embodiments of the present invention provide devices for continuously stacking fibers in a hydraulically settable mixture, allowing stacking with a different orientation or configuration. These configurations include parallel laying, spiral laying, cross-laying, or a combination thereof. In a “parallel configuration”, the fibers are laid approximately parallel to the longitudinal axis or the extrusion direction of the hydraulically settable product. In contrast, with the “spiral configuration” and the “cross configuration” (which is a variation of the spiral configuration), the fibers are laid at an angle α to the longitudinal axis, usually from 5 ^o (minimum) to 90 ^o (maximum). This angle may be referred to herein as the "offset angle", the "winding angle" or the "spiral angle". (Depending on the direction of rotation of the device for laying the fibers, i.e., clockwise or counterclockwise, the angle α can be positive or negative, but its absolute value will not exceed 90 ^o , since the angle 91 ^{o is} equivalent to the angle - 89 ^o ).

 The placement of continuous fibers in a hydraulically settable mixture without any significant twisting or other similar movement of the fibers introduced into the inner chamber of the extruder allows a parallel coaxial configuration of the fibers in the extrudable product. The spin of the fibers as they are introduced into the extruder makes it possible to obtain an extrudable product with a spiral configuration of fibers inside a hydraulically settable structural matrix. The cross configuration is ensured by winding the fibers in the opposite direction to the winding of the previously laid fibers. For example, winding one continuous fiber clockwise and a second fiber counterclockwise allows you to get overlapping fibers with a cross orientation, moreover, one fiber is wound at a positive angle relative to the longitudinal axis, and the second fiber is wound at a negative angle relative to the longitudinal axis.

 The concentration, or the ratio of the volume of fibers to a given volume of a hydraulically settable matrix of the extrudable product, is proportional to the number of fibers, their cross-sectional area and the value of the angle of winding of the fibers α. With an increase in any of these variable parameters or all of these parameters, the concentration or volume of fibers in the hydraulically settable matrix will increase. In particular, an increase in the winding angle α increases the laying frequency of each individual fiber, which simultaneously leads to a reduction in the distance between each turn and, accordingly, to an increase in the concentration (and also volume) of fibers per unit length of the extrudable product.

 By varying the concentration and (or) the angle of winding of the fibers placed in the extrudable hydraulically settable products of the present invention, it is possible to obtain various strength characteristics, elongation and toughness. In addition, depending on their chemical composition, the fibers themselves can have significantly changing characteristics of tensile and shear strength, as well as flexibility and elongation. These characteristics also depend on the diameter of the fibers, as well as on whether they consist of individual filaments, or of groups of interwoven or otherwise connected filaments forming a single composite fiber.

The main factor affecting the properties imparted by the wound fibers to the final cured article is the shear angle. Characteristics that depend on shear angle include tensile strength under pressure, tensile strength, and product flexibility. The preferred value of the shear angle depends on numerous factors, including the shape of the extrudable product, the type of fiber, the required strength characteristics of this product, as well as the cost of manufacturing. Fibers stacked at a small angle of winding, as a rule, define an elliptical section of the products in the form of a pipe or cylinder into which they are stacked. As the angle of winding increases to 90 ^{o the} eccentricity of the ellipse formed by the winded fibers decreases. When the winding angle is 90 ^o , the cross section of the product, determined by the fibers, will take the form of a circle.

If we assume that the extrudable product is a pipe, cylinder or other product with approximately circular cross-section, then such a product will have a radius approximately perpendicular to the longitudinal axis. In order to determine the direction and magnitude of the strength characteristics imparted by the fibers, it is advisable to determine the strength characteristics imparted by the fibers using vectors characterizing the strength in the radial and axial directions, respectively. If the angle of mixing of the fibers exceeds 0 ^o , but does not reach 90 ^o , then the fibers will provide both axial and radial component of strength. It can be expected that with a fiber winding angle not exceeding 45 ^° , the axial strength vector will typically exceed the radial strength vector. Similarly, it can be expected that when the angle of winding of the fibers exceeds 45 ^o , the vector of radial strength, as a rule, will exceed the axial strength vector.

 As a rule, fibers oriented mostly in the longitudinal direction and providing a larger axial strength vector will increase the tensile strength of the hydraulically settable product in axial, i.e. longitudinal direction. Conversely, fibers with a large angle of displacement relative to the longitudinal axis, i.e. fibers providing a larger radial strength vector will increase the circumferential tensile strength of a hydraulically settable product (in the case of pipes or other hollow structures, this indicator is called crushing strength (crushing) or tensile strength under the influence of internal pressure). To give strength in both directions, a combination of fibers with large and small angles of displacement can be used.

The angle of winding of the fibers α depends both on the translational speed of the extrusion ("V _c "), and on the peripheral speed ("V _r ") styling. In fact, the tangent of the angle α is proportional to the ratio of the peripheral speed to the translational extrusion speed (V _r / V _c ). Therefore, ceteris paribus, the higher the extrusion rate, the smaller the angle of winding of the fibers. Conversely, the greater the circumferential speed of the styling means, the greater the angle of winding of the fibers.

 The concentration of fibers inside the hydraulically settable matrix of the extruded product is directly proportional to both the number of fibers and their average winding angle α. As the number of fibers and their winding angle α increase, the fiber concentration increases. The greater the concentration, the less space remains between the individual turns of fibers. This allows for a more significant and uniform effect of the fibers on the hydraulically settable matrix of the extrudable product. Typically, fibers of small diameter, which are more closely adjacent to each other, provide imparting more uniform characteristics, for example, strength, flexibility and toughness, than in the case of fibers of large diameter.

 And finally, the relative laying depth of various individual fibers affects their spatial orientation, which, like the concentration and angle of winding, can affect the strength, flexibility and other characteristics of the final cured product. A more uniform distribution of the laying depth of individual fibers allows you to get the final product with more evenly distributed fibers, which improves the distribution of stationary or impact load acting on the extruded product.

 In most cases, the fibers are preferably positioned so as to ensure uniform strength of the product in all directions. Nevertheless, the optimal laying of fibers in the product will be determined by the specific functional requirements for it. The fibers can be immediately laid to the optimum depth, or their spatial position inside the hydraulically settable structural matrix can be changed by deepening the fibers after their initial laying. The laying depth of the fibers is determined by a number of independently acting factors together, such as the tension of the fibers, the viscosity of the mixture, the extrusion rate of the mixture, and the rotation speed of the fiber laying means.

 The fibers are drawn by the mixture from the styling means, mainly due to the frictional force between the mixture and the fibers, which is partially controlled by adjusting the viscosity of the mixture. However, as described above, in order to increase the workability of the hydraulically settable mixture in order to allow extrusion at minimum cost, it is preferable to lower the viscosity of the mixture while maintaining an adequate yield strength necessary to ensure dimensional stability. In a preferred embodiment of the present invention, these opposing factors are optimized. Excessively high viscosity can lead to excessive energy consumption, the impossibility of extrusion or to rupture of the fibers, while too low viscosity will cause the fibers to slip in the mixture and will not allow them to be laid evenly. As described above, the viscosity of the mixture can be varied using various methods, such as changing the packing density of the particles, increasing the concentration of water, or introducing additives such as dispersants or reagents that reduce the need for water.

 The fibers can be buried in a hydraulically settable structural matrix after they are pulled out from the styling means by maintaining optimal tension of the fibers during winding. The tension of the fibers causes the fibers to be pressed into the hydraulically settable structural matrix as the styling means rotate.

 The penetration depth of the fiber into the extrudable product is inversely proportional to the length of the fiber laid during the laying of any given turn, since the arc, the length of which is determined by the circumference of the extruded product, will be longer than the chord connecting the two end points of the arc. This length of the stacked fiber, in turn, is inversely proportional to the fiber tension. In other words, by increasing the tension of the winded fibers, it is possible to reduce the length of the fiber laid during rotation of the rotational laying means, which in turn leads to the pulling of the fibers inside the extruded material. By adjusting the fiber tension as well as the peripheral and extrusion speeds, one skilled in the art will be able to control the depth of penetration of the fibers into the extrudable material.

 In FIG. 8-29 show fibers laid in a hydraulically settable mixture by means of a device including means for continuously stacking the fibers in a hydraulically settable composition extruded to obtain the desired product. The fibers shown in FIG. 8 to 21 are inserted into the die or inner chamber of the extruder of the present invention; the inner chamber is hereinafter referred to as the “fiber stacking chamber”, the “inner die chamber” or simply “the die”. A specific embodiment of a device for continuously stacking fibers in a hydraulically settable composition is shown in FIG. 22 - 29.

 The methods and devices described below can also be used to process any plastic materials known in the industry or subsequently developed. The terms “plastic material” or “plastic materials” as used in the present patent description and the attached patent claims refer to any materials or mixtures, such as hydraulically settable mixtures (including cement mixtures), mixtures with an organic polymer binder, clay and water mixtures, thermoplastics, resins and polymers that have sufficient ductility for continuous extrusion of such materials or mixtures under pressure, but which also acquire sufficient form resistance immediately after extrusion of the die. By way of example, but without limiting the generality of the above definition, organic polymer binder mixtures that can be continuously extruded under pressure include organic polymer binders and mixtures described in US Patent Application Serial No. 08/218971, which is being considered concurrently with this application, entitled "Methods of forming articles with an organic polymer matrix with inorganic fillers", filed March 25, 1994 in the name of Dr. Per Just Andersen and Simon K. Hadson. For purposes of information disclosure, this application is incorporated into this application by this link.

 The shape stability of “ductile materials” that can be used in connection with the methods and devices of the present invention can be improved by increasing the number of fibers embedded in the ductile material, in particular spiral-wound fibers, and in particular cross-wound fibers. Thus, a “plastic material”, which typically has low shape stability in the case of extrusion without fibers, can acquire increased shape stability due to the reinforcing action of the fibers laid in the raw plastic mixture during the extrusion and laying of the fibers.

 In FIG. 8-10 show fibers introduced into an extruder die, stacked in a hydraulically settable mixture and wound in a spiral configuration. In FIG. 8 shows a longitudinal section of the device indicated by pos. 50 and intended for laying fibers during the extrusion of a hydraulically settable mixture, indicated by pos. 52. In FIG. Figure 8 shows how a hydraulically settable mixture 52 is extruded through a fiber stacking chamber 54 of a hydraulically settable mixture extrusion apparatus, typically a screw or piston extruder. The fiber stacking chamber 54 may be a single oblong die or several chambers and dies connected to each other. The hydraulically settable mixture advances along the fiber stacking chamber 54 in the extrusion direction indicated by arrow 56 to the means for laying the fibers into the hydraulically settable mixture.

 Each styling device is at least partially located inside the wall of the fiber stacking chamber 54 and communicates with both the fiber stacking chamber 54 and the outer surface of the device, which allows the fibers to enter the stacking chamber 54. The fibers come from the outer surface of the device 50, are introduced into a hydraulically settable mixture in the fiber stacking chamber 54 and are pulled off from the styling means due to internal friction or viscosity of the hydraulically settable mixture. Each styling means includes a device for introducing fibers from the outer surface into this means, a device for passing fibers through the means for laying, and a device for introducing fibers into a hydraulically settable mixture in the fiber-laying chamber 54. Between the outer surface of the receiving device 50 the device, the conductive device, the introducing device and the camera for laying the fibers are continuously connected, due to which the fibers are continuously placed in a hydraulically settable mixture as it moves through the fiber stacking chamber 54.

 In the embodiment of the device of the present invention shown in FIG. 8, a device for supplying fiber to the stacker is presented as an input for fibers 58; a device for posting the incoming fiber through the styling means is presented in the form of a channel 60; and the device for introducing fiber into the hydraulically settable mixture in the fiber stacking chamber 54 is provided in the form of a scooped tip 62. Fiber 64 is inserted into each fiber inlet 58 through the channel 60 and inserted through the scoop tip 62 into the fiber stacking chamber 54. A portion of the fiber stacking chamber 54 shown in FIG. 8 has a circular cross section; however, the fiber stacking chambers 54 may have any cross-sectional shape, length, or shape necessary for manufacturing the desired product.

 In FIG. 8 shows a conical chamber for laying fibers 54, the cross-sectional diameter of which gradually decreases towards the output end of the chamber for laying fibers to provide the required back pressure in the system. Back pressure helps maintain a constant pressure in the fiber stacking chamber or die, which increases the degree of compaction of the hydraulically settable mixture and the corresponding contact area between the hydraulically settable matrix and the fibers. Sealing the hydraulically settable mixture around the fibers helps to envelop the fibers, increase the uniformity of the mixture and reduce the number of voids within the mixture, which in total optimizes the contact between the fibers and the hydraulically settable mixture and helps to securely fix the fibers in the cured article. The counterpressure in the fiber stacking chamber 54 makes it possible to efficiently fill any grooves or slots created by the fibers entering the hydraulically settable structural matrix and cutting through it during the laying process, usually carried out by winding the fibers. Backpressure is particularly desirable if the fiber stacking chamber 54 is long and if a large number of fibers are introduced into the hydraulically settable structural matrix.

 The styling means shown in FIG. 8 to 10 are rotatable to allow winding of fibers in a typical helical or spiral configuration for laying the fibers in a hydraulically settable matrix as the hydrically settable mixture is extruded. The means for rotating the laying means (not shown in FIGS. 8-11) rotates the laying means around the fiber stacking chamber 54. The laying means can also maintain a stationary or fixed position with respect to the die to lay the fibers approximately parallel to the axis corresponding to the direction of extrusion. The styling means may be of any shape necessary to accommodate non-cylindrical and irregular fibers, such as roving or mats.

 The extrudable mixture passes through the scoop tips 62 (shown in longitudinal section in FIG. 9), envelops the threads protruding from the scoop tips 62 and entrains the fibers in the extrusion direction 56. The fibers are pulled from the scoop tips due to internal friction or viscosity of the hydraulically settable mixture. After the hydraulically settable mixture has solidified, the fibers will be firmly fixed in the hydraulically settable matrix, providing the above reinforcing and hardening characteristics. The fibers, together with the hydraulically settable mixture, form a continuous extrudable profile 66 of any desired length. The extrudable profile can also be cut into products of any desired length, which makes it possible to continuously produce even relatively small products. For example, in FIG. 9 shows the molding of an article 66 having the shape of a bar or bar.

 The design of laying means allows you to specify the configuration of the fibers inside the mixture and the depth of laying of the fibers inside the hydraulically settable matrix. In FIG. 10 is a cross-sectional view taken along line 10 where scoop-shaped tips 62 are visible protruding into the fiber stacking chamber 54, as well as the perimeter 68 of the article 66 after extrusion. The laying depth is determined (at least in part) by the length of the portion of the laying means that projects into the fiber stacking chamber 54. The laying depth also increases by increasing the tension of the fibers.

 The angle of placement of the styling means, which directly corresponds to the exit angle of the fiber (i.e., the angle at which the fiber exits the styling means), also affects the stress in the fiber that is laid in a hydraulically settable mixture. As a rule, the voltage in the fibers is minimized by minimizing the difference between the winding angle and the output angle of the fiber. This difference is minimized due to the placement of styling means at which the output angle is approximately equal to the winding angle. As the difference between the exit angle and the winding angle increases, the friction between the fiber and the winding means increases, which increases the tension of the stacked fiber. As described above, an increase in fiber tension generally leads to an increase in fiber laying depth, which is often undesirable.

 As described above, the styling means shown in FIG. 8-10, can also maintain a fixed position (as shown in Fig. 11. where a longitudinal section of the device is shown), which allows the fibers to be laid parallel to the longitudinal axis of the fiber stacking chamber 54. Other embodiments of the stacking means shown in FIG. 12, 13 and 14 can also rotate or maintain a stationary position. In FIG. 12 is a longitudinal sectional view of a device provided with styling means consisting of an input for fibers 70, a channel 72, and an input device with a pointed tip 74. The styling means of FIG. 12 maintains a stationary position for the parallel laying of fibers in a hydraulically settable matrix. In FIG. 13 is a cross-sectional view (along line 13) of the stacking means and the fiber stacking chamber 54 shown in FIG. 12. Here you can see the pointed tips 74, protruding into the fiber stacking chamber 54, and the shape of the product after extrusion.

 In FIG. 14 is a longitudinal sectional view of another embodiment of stacking means. All styling means in FIG. 14 consist of an input for fibers 76, a channel 78, and an input device in the form of a hollow needle 80. In another embodiment of the stacking means, the hollow needle can be inserted into the channel and moved inside the channel 78 to gradually increase its depth in the fiber stacking chamber 54 to change fiber laying depths within a hydraulically settable structural matrix. In addition, the fibers can be laid to a predetermined depth by designing laying means of any design in such a way as to ensure that the fibers are laid at a constant predetermined depth. The styling means shown in FIG. 8-14, are given only as an example, and not as a limitation of the scope of the present invention, and can be implemented in the form of other structures capable of arranging the fibers into a hydraulically settable structural matrix.

 The strength of the molded product can be further increased by introducing additional fibers into the mixture using one or more sets of styling tools offset from the first set of styling tools. For example, the second fiber may be placed closer to the surface of the matrix as compared to a previously laid fiber. In addition, you can apply a combination of several sets of rotational or stationary means of laying, which will allow you to place the fibers in various combinations or configurations. For example, fibers having an opposite direction to previously wound fibers can be stacked in a hydraulically settable mixture.

In FIG. 15 is a longitudinal section through a device 50 that extrudes a hydraulically settable mixture 52 in the extrusion direction shown by arrow 56 while stacking “cross” fibers 64 into a hydraulically settable mixture 52. Two sets of rotational stacking means consisting of an inlet 70, channel 72 and the pointed tip 74, rotate in opposite directions and provide winding of the fibers inside the structural matrix in opposite directions, which provides a cross-configuration of the fibers. The styling means used to place the fibers in a cross-configuration include styling means and means for spinning at least one fiber at a certain speed in the first direction relative to the die, as well as styling means and means for twisting at least one other fiber at a certain speed in a second direction opposite to the first direction. The angle between the fibers with the opposite orientation is usually in the range from about 10 ^o to 180 ^o . Although the angle between the cross fibers can be less than about 10 ^° , in practice cross fibers with an angle of less than about 10 ^° can generally be considered as fibers with a substantially parallel orientation, as in the case of fibers with a winding angle of less than about 5 ^o .

 In FIG. 16 is a longitudinal sectional view of an apparatus 50 capable of extruding a hydraulically settable mixture 52 in an extrusion direction 56 while simultaneously laying fibers 64 in a hydraulically settable mixture 52 in a parallel configuration and a cross configuration. In the direction of extrusion 56, the fibers are first laid with fixed laying means consisting of an input 70, a channel 72 and pointed tips 74 and providing parallel laying. Cross fibers are laid over parallel fibers, which is done using two sets of rotational laying tools, which also consist of an input 70, a channel 72 and pointed tips 74 and which rotate in opposite directions, providing laying in a hydraulically settable mixture of fibers having the opposite orientation.

 Although, as a rule, the greater the absolute strength of the fibers, the less fibers will be required to harden the product, nevertheless, it is preferable to provide a sufficient distribution of fibers throughout the product to distribute the desired strength characteristics throughout the product. Based on the information presented here, the material technology specialist will be able to determine in advance or after a little experimental preparation the actual dimensions, strength characteristics, number and orientation of the fibers that should be placed in a hydraulically settable matrix to obtain the required characteristics.

 It may also be desirable to place different types of fibers in the same product. In addition, some materials can be extruded together with a hydraulically settable mixture and continuous fibers. A hydraulically settable mixture and fibers can be extruded around any material, or some material can be extruded around a mixture and fibers. For example, the mixture and fibers can be extruded around a graphite rod to form pencils, or the coating material can be extruded around the mixture and fibers.

 One of the main advantages of the methods and devices of the present invention is the ability to manufacture products of various shapes with the selective placement of fibers of different types and concentrations within the products. The shape of the product is determined mainly by the shape of the chamber for laying fibers 54, in particular, the cross-sectional shape of this chamber 54, since the hydraulically settable mixture is extruded in the form of a continuously extruded product. It is also possible to manufacture products with internal cavities or a hollow internal part, for which device for extruding a hollow product from a hydraulically settable mixture in combination with an extruder and fiber-laying means are used. The configuration or spatial orientation of the fibers placed in a hydraulically settable structural matrix depends on the design of the laying means, including the laying depth of the fibers, as well as the rotation speed of the laying means.

 When designing the desired product, the choice of fiber types and configuration is determined primarily taking into account the loads to which the product will be subjected. For example, an I-beam, which will be subjected to transverse loading, should preferably be provided with fibers that are remote from the central axis of the stretched element, which will increase the flexibility of the beam and maximum fracture load. In FIG. 17 shows a general view of a device 50 provided with stacking means arranged around a sectional view of a fiber stacking chamber 54, which is in the form of an I-beam. The device 50 of FIG. 17 forms an article 66 having the shape of a continuous I-beam. The profile obtained by continuous extrusion can be cut into individual I-beams using means for cutting extruded profiles. Such cutting means may be a rotary knife 82, a translational knife of the guillotine type, a saw or any other device capable of cutting a hydraulically settable structural matrix and the fibers inside it.

 Products such as boards, two-by-four-inch bars, plywood, countertops, corrugated boards, flat sheets and roofing tiles can be obtained by extruding a hydraulically settable mixture and laying the fibers in parallel in a matrix. In FIG. 18 is a perspective view of an apparatus 50 with a slit-like fiber stacking chamber 54 and stationary stacking means located around the fiber stacking chamber 54, which enables the formation of a flat hydraulically settable sheet 66 with parallel fibers.

 Non-circular cross-sectional products can be molded, which nonetheless contain fibers wound almost spirally with respect to the direction of extrusion. Such articles are formed by extruding a hydraulically settable mixture through a fiber stacking chamber provided with a first chamber having an approximately circular cross section and a second chamber having a substantially non-circular cross section. In the General case, the second chamber is stationary in space, communicates with the first chamber, shifted relative to it in the direction of extrusion and provided with an outlet or hole for extrusion of a hydraulically settable mixture. The styling means communicate with the first chamber and lay the fibers in a hydraulically settable mixture as it moves through the first chamber. The hydraulically settable mixture passing through the first chamber typically has an approximately circular cross section, but at the outlet of the second chamber may acquire a non-circular cross section determined by the cross-sectional shape of the second chamber. The change in the cross-sectional shape of the mixture conducting from the first chamber to the second can be gradual or sharp, but must be calculated taking into account the cross-sectional shape and the configuration of the laying of fibers in the extrudable product.

 As shown in a general view of the device 50 in FIG. 19, the product with a non-circular cross section still has a matrix with almost spiral (helical) winding of the fibers in the direction of extrusion. The device 50 of FIG. 19 is provided with a chamber for laying fibers 54, shown in section to its “outlet end” or the point of transition to the “outlet die”, which is a means for exiting the mixture and having a different cross section corresponding to the shape of the desired product. The corners and perimeter of the product, if desired, can be strengthened in parallel with stacked fibers.

 Means for extrusion of a hydraulically settable mixture in the form of hollow articles can also be placed inside the fiber stacking chamber 54, which will make it possible to obtain tubular products with a hollow section, such as pipes or hollow cylinders. By way of example, but not by way of limiting the scope of the invention, means for extruding a hydraulically settable mixture in the form of hollow bodies may include at least one mandrel placed in a fiber stacking chamber 54. The mandrel may have any shape and any cross-section that allows extrusion mixture around her. It may be desirable to give the mandrel a conical shape with a smaller diameter at the beginning of the fiber stacking chamber and a larger diameter at the end of this chamber. The conical mandrel helps maintain back pressure in the system, which, in turn, helps seal the mixture and increase the contact area between the mixture and the fibers.

 The mandrels are also useful for forming tubular articles containing fibers in an approximately helical orientation in the extrusion direction and at the same time having a non-circular section of the inner cavity with a round or non-circular outer surface. In the case of a mandrel used to form articles with a non-circular inner hole, a round outer surface and approximately spiral orientation of the fibers, the cross-section of the mandrel in the extrusion direction gradually changes from approximately circular to non-circular. Laying means are placed inside the walls of the chamber for laying fibers 54 and provide winding of the fibers in the mixture as it passes along the mandrel section, which has an approximately circular cross section.

 The fibers in a hydraulically settable mixture extruded around the mandrel, the cross section of which in the extrusion direction gradually changes from approximately circular to non-circular, can remain in the initial stacking position or can be additionally moved so that the position of the fibers relative to the cross section of the hydraulically settable structural matrix approximately matches the shape of the mandrel on the output of the mixture from the chamber for laying fibers 54. The final position of the fibers corresponding to the shape of the mandrel at the exit of the mixture from the kame Layers for laying the fibers 54 can be ensured by laying the fibers at a small distance from the mandrel, so that the changing contour of the mandrel allows the fibers to move inside the matrix. A very close coincidence of the position of the fibers with the shape of the mandrel at the output end is ensured by maintaining approximately the same diameter (or transverse size) of the mandrel as the mandrel contour transitions from circular to non-circular cross section, which makes it possible to obtain almost spiral fibers whose position corresponds to the shape of the inner hole of the obtained product .

 Tubular products containing fibers in an approximately spiral orientation in the direction of extrusion, and at the same time having a non-circular section of the internal cavity with a non-circular shape of the outer surface, are formed by extrusion of a hydraulically settable mixture around a mandrel, the cross section of which in the extrusion direction gradually changes from approximately circular to non-circular . The fiber stacking chamber 54 is provided with a first chamber having an approximately circular cross section and corresponding to a mandrel portion with an approximately circular cross section, and a second chamber having a substantially non-circular cross section, as described above. The change in the cross-sectional shape of the mixture during its transition from the first chamber to the second can be gradual or sharp.

 As shown in a general view of the device 50 in FIG. 20, such products can be manufactured using a sectional view of a fiber-laying chamber 54, which at the location of the styling means has an approximately circular section, then gradually turning into a non-circular section, as well as a mandrel 84, the cross-section of which likewise changes from circular to non-circular. The mandrel 84 can also be designed so that the sections of the transition sections of the contour along its length have approximately the same perimeter, which will improve the shape and increase the strength of the spiral winding.

 In addition, several mandrels for forming multi-section products, such as hollow bricks, honeycomb structures or other multi-cell structures, can be placed in the fiber stacking chamber. In FIG. 21, hollow bricks are shown being molded by means of a device 50 provided with three mandrels 84 shown in a cutout of a fiber stacking chamber 54 and by means of stacking means placed around a fiber stacking chamber 54 having a rectangular cross-section. As with other extrudable profiles, a continuous “brick” can be cut into pieces of the desired length using cutting means, such as a cutter 82, to form individual bricks.

In FIG. 22 to 29 show another embodiment of a device 50 designed to lay fibers in a spiral configuration, a cross configuration, a parallel configuration, or any combination of these configurations. Fibers can be stacked by device 50, as shown in FIG. 22 to 29, during the extrusion of a hydraulically settable mixture. Simultaneous execution
extrusion and laying of fibers in hydraulically settable mixtures provides the possibility of continuous production of products reinforced with continuous fibers with spiral winding.

 In FIG. 22 shows a general view, and in FIG. 23 is a front view of a device 50 provided with a fiber stacking chamber 54, which communicates directly with the inner chamber 24 ′ of the piston extruder 20. Three ring feeders are shown outside the fiber stacking chamber 54, shown at numbers 100, 102 and 104, on which the means for storing and continuously supplying fibers 64 to stacking means (not shown in FIGS. 22 and 23), which, in turn, introduce fibers into the fiber stacking chamber 54. A set of stationary stacking means placed around the stacking chamber in curl 54 receives the fiber with fixed feeder ring 100, which retains substantially motionless position with respect to the placing means. One set of rotary stacking means receives fibers from the rotary ring of the feeder 102. Another set of rotational stacking means receives fibers from the rotary ring feeder 104, and this set of stacking means rotates in the opposite direction to the rotation direction of the first set of rotational stacking means. The rotary ring feeders 102 and 104 maintain a substantially fixed position relative to the rotational stacking means, and the mechanism for rotating the ring feeder relative to the extruder die also rotates the stacking means relative to the extruder die, which provides spiral fiber laying.

 Each ring feeder consists of a frame of the ring feeder 106 and at least one fiber dispenser or dispenser, such as bobbins with fibers 108. The fiber dispensers are located on the ring feeders 100, 102, 104. A fiber dispenser without a ring can also be used. feeder, which will provide storage and continuous supply of fibers to the styling means. By way of example, but not by way of limiting the scope of the present invention, a fiber dispenser capable of storing and continuously feeding fibers, but not placed on an annular feeder, may be a conventional creel, used in conventional filament winding methods.

 The fiber dispenser can either rotate freely on the spindle without tension, or be equipped with a tensioner that provides a predetermined tension of the fibers and allows you to change the tension of the fibers 64 supplied from the dispensers, such as the tensioner 110. The tensioner allows the fibers to penetrate into the hydraulically settable mixture during rotation of the means laying relative to the fiber laying chamber 54. Each tensioner 110 in the embodiment shown in FIG. 22, comprises a hollow spindle (not shown) with an internal thread (not shown) into which a threaded bolt (not shown) is screwed with a head 112 engaging with the bobbin head with fibers 108. An increase or decrease in the contact force between the bobbin head with fibers 108 and the head of the bolt 112, which is usually carried out by tightening or loosening the threaded bolt, leads to a change in the tension of the feed fiber. The tensioner may also be provided with a spring placed around the spindle between the bolt head 112 and the bobbin with fiber 108. In another embodiment of the tensioner, a mechanical drive of the bobbins 108 is provided.

 The mechanism for rotating the styling means is engaged with the rotary ring feeders 102 and 104, which are rigidly attached to the rotational styling means and therefore provide rotation of the rotational styling means. The embodiment of the rotational mechanism shown in FIG. 23, consists of an engine 114, a belt 116, and a groove 118 on each respective ring feeder for engaging with a belt 116. Each engine 114 drives each belt 116, which in turn drives a respective ring feeder. The motors 114 are mounted on a support frame 120, which is attached to the extruder 20. In addition, the support frame supports the device using elements 122 attached to the clamps 124.

 Another embodiment of the rotary mechanism includes an engine that rotates the sprocket, which, in turn, engages with chain links, which also mesh with the teeth on the circumference of the ring feeder, thereby causing the rotary ring feeder to rotate. Another embodiment of the rotary mechanism is equipped with an engine rotating an asterisk, which is directly engaged with the teeth on the circumference of the annular feeder, thereby bringing the rotary annular feeder into rotation. The rotating mechanism can be equipped with numerical controls to improve accuracy. The rotary mechanism is also equipped with controls with a feedback mechanism that provides control and regulation of the rotational speed depending on the speed of extrusion. The rotating mechanism can be implemented in any other design that provides direct rotation of the styling means, or the rotation of an annular feeder attached to the styling means. Of course, the above-described rotating mechanisms are given only as an example, but not to limit the scope of the present invention.

 The components of the device 50 and the path of the hydraulically settable mixture along the device 50 are best seen in FIG. 24 and 25. In FIG. 24, in sectional view, of the device 50, and FIG. 25, where this device is shown in perspective with a spatial separation of the parts, the fiber-laying chamber 54 consists of an opening 130 of the inlet spinneret 132, an opening 134 of the rotary yarn guide carriage 136, an opening 138 of another rotational yarn guide carriage 140 and an opening 142 of the output spinneret 144. Hydraulically settable mixture continuously extruded from the inner chamber 24 'into the hole 130 of the inlet die 132, through the holes 134 and 138 of the rotary carriage of the thread guide channels 136 and 140, and exits through the hole 142 of the outlet die 144.

 The cross section of the fiber stacking chamber 54 may be constant over the entire length of the fiber stacking chamber 54 or change its shape and size. The cross section of the fiber stacking chamber 54 may be of any shape, including, but not limited to, the shape of a circle, square, ellipse, or triangle. In FIG. 24 shows a fiber stacking chamber 54 with a circular cross-section along the entire length of this chamber with a slightly decreasing diameter in the extrusion direction. The hydraulically settable mixture is extruded through the first hole and enters the second hole, the diameter of which is smaller than the diameter of the first hole, which allows the mixture to be densified further and the fibers to be placed inside the hydraulically settable structural matrix during fiber laying. As shown above, in the General case, it is desirable that the cross-section of the chamber for laying fibers is reduced towards the exit (or die) to provide back pressure in the system, which helps to fill the grooves inside the hydraulically settable structural matrix.

 As shown in FIG. 24, the fiber stacking chamber may also be provided with a mandrel 84 for forming hollow cylinder products, such as pipes. The mandrel may have a non-conical or conical shape, as shown in FIG. 24 to facilitate backpressure in the system, and may be housed in a fiber-laying chamber having a conical or non-conical shape, as described above. When using the mandrel in the piston extruder 20, it is necessary to fix the mandrel in the extruder 20 with a crosspiece 150 located between the mandrel 84 and / or the extruder 20. The crosspiece 150 is provided with conical legs 152 directed from the center to the perimeter, which allows a hydraulically settable mixture to flow around the legs 152 and close again after passing around the legs 152. The crosspiece 152 is not necessary if the device 50 is attached to a screw extruder.

 In order to provide a parallel configuration for laying the fibers in a hydraulically settable mixture, the fibers are fed from bobbins 108 located on the stationary ring feeder 100 to the chamber for laying the fibers 54 through stationary laying means located near the inlet die 132. The hydraulically settable mixture passes through the inlet of the inlet 130. 132 and enters the hole 134 of the rotary yarn guide carriage 136. An annular feeder is located in a girth and is stationary mounted on the input die. The fibers are fed through the inlet window 58 and channel 60 and delivered to the scooped tip 62, from where they are laid in a hydraulically settable matrix.

 In order to obtain a helical or spiral configuration of the fibers in the hydraulically settable matrix, any of the ring feeders 102 or 104 can be rotated while feeding the fibers from the bobbins 108 into the stacking means, which allow the fibers to be stacked in the matrix and rotate together with the rotary ring feeders. The rotary annular feeder 102 delivers the fibers to the styling means located inside the rotary carriage of the thread guide channel 136, which is fixedly mounted on the rotary annular feeder 102 using a clamping sleeve 160.

 The rotary yarn guide carriage 136 consists of a front section 162 with a flat end 164 and a convex end 166 with grooves 168, as well as a rear section 170 with a flat end 172 and a concave end 174. The convex end 166 of the front section 162 and the concave end 174 of the rear section 170 are aligned with a friend and bolted together.

 An entrance window for fibers 58, channels 78 and pointed tips 74 located inside the yarn guide carriage 136 are means for laying continuous fibers in a hydraulically settable matrix. Channels 78 are formed by grooves 168 in the convex end 166 and the concave end 174 after the combination of the convex end 166 and the concave end 174 is ensured. The angle of introduction of the fibers into the hydraulically settable mixture can be changed by changing the inclination of the convex end 166 and the concave end 168.

 The clip 160 contains a ball bearing assembly 178 mounted on the flat end of the front section 162, and the other clamping clip 180 contains another ball bearing assembly 182 mounted on the flat end 164 of the rear section 170. Each ball bearing assembly is provided with a tubular neck 184 and a sponge 186. The ends of the hole 134 enter the tubular journals 184 of both ball-bearing units 178 and 182 and concentric with them. The sponge 186 of the ball-bearing assembly 178 enters the groove of the clamp 124 together with the sponge 186 of the inlet die 132. The ball-bearing assemblies 178 maintain a relatively stationary position when rotating the rotary yarn guide carriage 136.

 In the direction of extrusion, the mixture flows from the hole 130 of the rotary yarn carriage 136 into the hole 138 of another rotary yarn carriage 140. At the hole 138, the fibers are laid in a hydraulically settable mixture using laying tools consisting of an input window for fibers 58, channels 78 and pointed tips 74 located inside the rotary yarn guide carriage 140. The fibers are fed to the laying means from the bobbins 108, placed on the rotary ring feeder 104, which is stationary attached to the rotary thread a carriage 140 via a clamping collar 188.

 The rotary filament carriage 140 shown in the figure is structurally identical to the rotary filament carriage 136. The rotary filament carriage 140 consists of a front section 190 with a flat end 192 and a convex end 194 with grooves 168, as well as a rear section 198 with a flat end 200 and a concave end 202. Convex the end face 194 of the front section 190 and the concave end 202 of the rear section 198 are aligned with each other and bolted together.

 Continuous fiber stacking tools located within the rotary yarn guide carriage 140 include an fiber entry window 58, channels 78 and pointed tips 74. Channels 78 are formed by grooves 204 in the convex end 194 and the concave end 202 after aligning the convex end 194 and concave end 202. The angle of fiber entry into the hydraulically cured structural matrix can be controlled by changing the slope of the convex end 194 and the concave end 202. The inclination of the convex end 194 and the concave end 202 can also be adjusted It can be used to reduce the load on the fibers when placing the fibers in a hydraulically settable mixture, as well as to resist the back pressure existing in the fiber stacking chamber 54.

 Ball bearing assembly 206 is held in the flat end face 192 of the front section 190 with a clamping sleeve 188, and ball bearing assembly 208 is held in the flat end face 200 of the rear section 198 with a clamping sleeve 210. The ball bearing assemblies 206 and 210 are provided with tubular necks 184 and jaws 186. Rotary thread guide the carriage 140 with the hole 138 rotates inside the necks 184 of the ball bearing units 206 and 208, while the ball bearing units 206 and 208 themselves maintain a relatively stationary position. The sponge 186 of the ball bearing assembly 182 enters the groove of the clip 124 together with the sponge 186 of the ball bearing assembly 206.

 The rotary yarn guide carriage 136 and the rotary ring feeder 102 are structurally identical to the rotary yarn guide carriage 140 and the rotary ring feeder 104, but the rotary yarn guide carriage 136 and the rotary ring feeder 102 rotate in the opposite direction to the rotation of the rotary yarn carriage 140 and the rotary ring feeder 104. In addition to although identical configurations are shown in the figure, the designs may also vary to vary the laying depth, output angle and winding angle.

 The hydraulically settable mixture and the continuous fibers pass from the bore 138 of the rotary yarn guide carriage 140 into the bore 142 of the exit spinneret 144, which ends with the fiber stacking chamber 54. The exit spinneret 144 is provided with a sponge 186, which enters the groove of the clip 124 together with the sponge 186 of the ball bearing assembly 208. Ball bearing assembly 208 and output die 144 maintain a relatively stationary position during rotation of the rotary yarn guide carriage 140.

 When the device 50 is operating, as the hydraulically settable mixture is pushed through the fiber-laying chamber 54, the fibers that are laid using the laying means adhere to the hydraulically settable mixture on or near the surface of the extrudable mixture, thereby causing the fibers to stretch out of the laying means as advancing the mixture. Fibers can be fed for laying in the matrix of the product using a single ring feeder to obtain the desired configuration of the fibers, or using several ring feeders to provide laying in several configurations. The cross configuration of the fibers can be obtained in cases where the laying of fibers is carried out by means of laying, rotating together with both ring feeders 102 and 104. In addition, the fibers can be laid in a hydraulically settable matrix simultaneously in a cross and parallel configuration, due to the supply of fibers to the laying means from the fixed ring feeder 100 and the rotary ring feeders 102 and 104.

 In FIG. 26, 27, 28, and 29 show three-dimensional images of articles 66 continuously extruded in the form of pipes using device 50 and having a different configuration of fibers inside the pipes. The fiber configurations are shown in FIG. 26-29 using dashed lines. In FIG. 26 to 29 show various embodiments of the device 50 shown in FIG. 22 - 25, which illustrates the possibility of obtaining various configurations of fibers in the product using different embodiments of the present invention.

 In FIG. 26 shows a pipe in which the fibers extend parallel to the length of the pipe, since they are laid using a set of fixed laying means arranged in a circle around a chamber for laying fibers 54 in a fixed yarn guide carriage 214, shown in section. In FIG. 27 shows a pipe in which the fibers are placed along a helical or spiral line along the length of the pipe, since they are laid using a set of rotational laying means arranged in a circle around the chamber for laying the fibers 54 in the rotary yarn guide carriage 136, shown in section.

 In FIG. 28 shows a pipe in which the fibers are laid along the pipe in a cross configuration. Fibers are fed from the dispensing spools 108 located on the rotary ring feeder 106 to the rotational stacking means housed in the rotary yarn guide carriage 140, shown in section. The rotary ring feeder is indicated by a dotted line to indicate that the fibers are fed to another set of rotational styling devices and introduced into the mixture. FIG. 29 is similar to FIG. 28, but the device 50 is shown with a fixed annular feeder 100 indicated by dashed lines to indicate that the fibers are fed into a set of fixed stacking means and introduced into the mixture. The pipe shown in FIG. 29 is provided along its length with fibers laid in both a cross and a parallel configuration using appropriate stacking means. The embodiment of the invention shown in FIG. 29 can also be used to obtain the same fiber configuration as in FIG. 26 - 28, for which only one or two of the available ring feeders should be used together with the corresponding sets of styling devices.

IV. Examples of preferred embodiments of the invention
To date, numerous tests have been carried out to compare the rheological and extrusion characteristics of various hydraulically settable mixtures with various compositions. The following are specific examples of formulations extrudable in accordance with the present invention. These real-world examples also include a description of the hypothetical placement of fibers within hydraulically settable blends during extrusion. In addition, a number of hypothetical (“predictive”) examples are included, based on actual compositions of the mixtures subjected to extrusion, or such compositions from which, based on experience, we can expect to ensure the performance of the characteristics described below. Real examples are described in the past tense, while hypothetical examples are described in the present tense to distinguish between these two kinds of examples.

 Typically, examples relate to the laying of continuous fibers in hydraulically settable mixtures having different levels of water deficiency and particle packing density, as well as different concentrations, for example, hydraulically settable binder, aggregates, short fibers, rheological modification agents and other additives to to obtain mixtures with different flow properties during extrusion under pressure, as well as various degrees of form stability after completion of extrusion of the product and termination pressure action.

Examples 1-9
Hydraulically settable mixtures containing 4 kg of type 1 Portland cement, 6 kg of fine-grained silica sand, 50 g of Tylose ^® FL 15002 reagent and water in various concentrations were mixed and extruded through a die using a piston extruder. Fine silica sand had a natural particle packing density of about 0.55 and particle sizes in the range of about 30 to 50 microns. When mixed with a Portland cement of type 1, the particles of which have a particle size in the range of about 10 to 25 μm, the packing density of the particles of the resulting dry mixture was about 0.65, which represents only a slight increase compared to the natural packing density of the particles of both materials. The natural packaged volume of cement and sand was 5.504 liters, and the pore volume was 1.924 liters.

 The volume of water in the mixtures was changed in the following order to determine the extrusion processability of the mixtures at different levels of water deficiency (see table. 1).

 In examples 1 and 2, the numbers in parentheses in the “% deficit” column indicate that excess water was used. This means that the volume of water introduced into the mixture exceeded the volume of internal voids (or pores), which amounted to 1.924 liters. As a result, these mixtures were characterized as “very liquid” and could not be extruded to provide a form stability sufficient for the products to retain their shape without external support. Similarly, although the mixtures of Examples 3 and 4 were less liquid and were characterized as “very soft,” they could not be extruded to provide a form stability that was sufficient for the products to fully retain their shape without external support. However, as the water volume further decreased, the shape stability of the extrudable products improved to such an extent that the extrudable product could maintain its shape without external support.

 The mixture according to example 5 was characterized as "soft", but allowed the extrusion to be performed at relatively low pressure and to obtain an object with good shape stability. The mixtures of Examples 6 to 9 were extruded with increasing pressure as the water volume decreased, and shape stability increased as the amount of water decreased. As the water deficit and extrusion pressure increased, the level of compaction of the mixture also increased, which ensured an improvement in particle packing and an increase in the density of the extruded material. After curing the mixtures, the megapascals expressed tensile strength of the solid material obtained by each example was, respectively, 2.4, 3.1, 5.2, 15.2, 28.2, 30.3, 32.2, 35 , 0 and 38.0.

 Laying the fibers in the mixture significantly changes the characteristics of the mixtures and the final cured products obtained from them, which in particular relates to the tensile strength of the products. Any continuous fibers can be used, including fiberglass, aramid fibers, carbon fibers, graphite fibers, polyethylene fibers and other organic fibers.

 The mixtures of Examples 5 to 9 were successfully extruded to produce cellular (i.e., multi-cell) structures, rods, and window frames. The mixtures of examples 6 to 9 were also extruded to produce pipes with different wall thicknesses. A pipe extruded from the mixture of Example 7 had a wall thickness of 25% of the pipe cavity size; a pipe extruded from the mixture of Example 8 had a wall thickness of 15% of the pipe cavity size; and a pipe extruded from the mixture of Example 9 had a wall thickness of 10% of the size of the pipe cavity. The wall thickness can be further reduced by reinforcing the pipe with fibers.

Examples 10-13
In the mixture of examples 5 to 9, various volumes of short fibers are added, expressed as a percentage of the volume of all solid components in the hydraulically settable mixture:
Example - Fiber
10 - 1%
11 - 2%
12 - 3%
13 - 4%
The type of fiber added depends on the characteristics and performance requirements of the extruded product. However, as a rule, increasing the tensile strength of the fibers will provide an increase in the tensile strength of the extrudable product. However, the nature of the fixing or pulling of the fibers in the hydraulically settable matrix under the influence of stresses and strains will depend on other factors, such as the ratio of the diameter and length of the fibers, the length of the fibers and their reaction with the hydraulically settable binder. As the concentration of short fibers increases, the tensile strength and ductility of the cured extruded products also increase. However, when laying in a hydraulically settable matrix of continuous fibers, the parameters of tensile strength and ductility of the product due to the fibers change slightly.

Example 14
The operations of Examples 1-9 were repeated, except that prior to extrusion, the amount of Tylose ^® FL 15002 reagent in the hydraulically settable mixture was increased to 100 g. Increasing the concentration of Tylose ^® reagent contributed to the extrusion process by improving the lubrication between the particles themselves and between particles and walls of the extruder and die. In addition, an increase in the concentration of Tylose ^® reagent slightly improved the dimensional stability of the products, although not twice. An increase in the concentration of the Tylose ^® reagent has practically no effect on the draw of continuous fibers with the mixture, since the viscosity increases slightly.

Example 15
The operations of examples 1-9 were repeated, except that 160 g of a sulfonated condensate of naphthalene-formaldehyde used as a dispersant were introduced into the mixture. First, hydraulic cement, water, dispersant and at least a portion of the aggregate material were mixed in the mixer with high shear for about 10 minutes. Thereafter, the Tylose ^® FL 15.002 reagent and the remaining aggregate (if provided) were mixed into the mixture using a low shear mixer. The dispersant provided a more fluid mixture while maintaining the same concentration of water.

 The resulting hydraulically settable mixtures had a reduced viscosity, which facilitated their extrusion at a relatively low pressure in comparison with the mixtures of Examples 1 to 9. However, a decrease in viscosity generally impairs the function of drawing continuous fibers into the mixture. In addition, extruded products in the general case had less form stability than their counterparts in Examples 1 to 9. However, to obtain a mixture with the same degree of extrusion processability and form resistance, in this example, significantly less water was required than in examples 1 - 9 This made it possible to obtain final cured products with increased strength due to a reduction in the concentration of water in hydraulically settable mixtures, which corresponds to the strength equation.

Example 16
The operations of examples 1-9 were repeated, with the exception that 0.8 kg of micronized silica was also added to each mixture. Due to the high specific surface area of the particles of silica fume, the mixtures comprising this aggregate had an improved dispersion, especially when a dispersant was added to the mixture.

 Although it could be assumed that in the case of adding microfine silica, it would be necessary to increase the concentration of water to ensure the same level of workability (plasticity), it turns out that the extremely small particle size of microfine silica relative to other particles in hydraulically settable mixtures significantly increased the packing density of the particles. Therefore, the mixtures had significantly lower porosity, which reduced the amount of water required to lubricate the particles. As a result, the extrusion processability of mixtures containing microgranular silica was approximately the same as for mixtures not containing microgranular silica. However, silica fume increased the yield strength and internal adhesion of the mixtures, which led to an increase in the form stability of extruded products. The pulling force of continuous fibers also increases, but it is difficult to control the placement of fibers by increasing their tension. The effect of pulling the fibers from the matrix of the cured article is reduced, since the fibers have a large contact area with other components of the hydraulically settable structural matrix.

 In the following examples, particle sizes of silica sand aggregate were increased to increase the packing density of the particles of the resulting mixture. The resulting increase in particle packing density ensured the manufacture of extruded products with increased strength. This contradicts the traditional notion that the smallest particles available should be used to increase the density and therefore the strength of the final cured article. On the contrary, a gradual increase in the particle size of silica sand, which led to an increase in the ratio of the size of the particles of aggregate and particles of cement to achieve more and more preferred ranges, in fact, provided an increase in the density of the mixture.

Examples 17 to 36
The same concentrations and types of hydraulically settable binder and aggregate were used as in Examples 1 to 9, with the exception that the volume of added water changed significantly in smaller increments in the order shown in Table. 2.

 The pressures required for the extrusion of the mixtures of the present examples were similar to the values of the extrusion pressure of the mixtures of Examples 1 to 9. As in some of the examples described above, the mixtures of Examples 17 to 22 were too liquid and did not provide sufficient form stability after extrusion. In addition, due to the excess initial volume of water, these mixtures showed a relatively low strength in accordance with the strength equation. Although the mixture of Example 23 was extrudable, only articles of large cross section and simple shape retained their shape without external support. The mixtures of Examples 24 to 33 were extrusion at approximately the same pressure range as for the mixtures of Examples 5 to 9. However, the mixtures of Examples 34 to 36 could not be extruded using extrusion equipment available to the inventors. Too liquid mixtures do not have sufficient viscosity to draw continuous fibers laid in such liquid mixtures.

Examples 37-53
Hydraulically settable mixtures containing 4 kg of Portland cement, such as 1.6 kg of silica sand, 50 g of Tylose ^® reagent and water in various concentrations were mixed and extruded through a die using a piston extruder. Fine silica sand had a natural particle packing density of about 0.55 and particle sizes in the range of about 50 to 80 microns. When mixed with type 1 Portland cement, the particles of which have a particle size in the range of about 10 to 25 μm, the packing density of the particles of the resulting dry mixture was about 0.7. which represents only a slightly larger increase compared with the natural packing density of the particles of both materials than the increase achieved in examples 1 to 9.

 The volume of water in the mixtures was changed in the following order to determine the extrusion processability of the mixtures at different levels of water deficiency (see table 3).

 In Examples 37 to 41, the numbers in parentheses in the “% deficit” column indicate that excess water was used. As before, these mixtures were "very liquid" and could not be extruded to provide a form stability sufficient for the products to retain their shape without external support. As in the examples described above, the mixtures of Examples 42-50 were extruded to produce a variety of form-resistant products, such as honeycomb structures, rods and window frames. Due to the higher packing density of the particles of the mixtures of Examples 37-53 in comparison with the mixtures of Examples 1-9, maintaining a constant water concentration reduced the degree of water deficiency and, consequently, increased fluidity and lower viscosity.

 The increased packing density of the particles also improves the fixation of continuous fibers in the cured product molded from such mixtures, since the contact area of the fibers with other components of the hydraulically settable structural matrix increases.

 As the degree of water deficiency increases, the possibility of extrusion of pipes with thinner walls is created. In addition, the strength of the final cured products was higher than that of products made from mixtures with a lower packing density of particles, which corresponds to the strength equation. A further decrease in the wall thickness of the pipes is possible due to the laying of continuous fibers in such mixtures.

 However, while reducing the mass of water to 0.4 kg or less and increasing the degree of deficit to about 75% or more, extrusion of mixtures using existing equipment was impossible; however, it is believed that the use of a higher pressure extruder will allow extrusion of such mixtures, although this may be less appropriate. Thus, the mixture of examples 51-53 could not be extruded.

 From these examples, it can be seen that increasing the packing density of solid particles while maintaining the volume of water introduced into the mixture provides mixtures with a lower degree of water deficiency. With the same volume of water, this makes it possible to extrude more densely packed mixtures under reduced pressure. In addition, increasing the packing density of the particles leads to an increase in the area of frictional contact with continuous fibers, which increases the pulling force of continuous fibers placed in the mixture.

Examples 54-67
Hydraulically settable mixtures are re-prepared according to examples 40-53, except that in this case silica fishing line particles with sizes in the range of about 60 to 120 microns are used. The packing density of the particles of the resulting mixture of sand and cement is about 0.75. While maintaining the volume of water used in examples 40 to 53, the degree of water deficiency in the mixtures changed (see table. 4).

 As in the above examples, maintaining a constant volume of water while increasing the packing density of the particles allows us to obtain a hydraulically settable mixture that can be extruded at lower pressure, which can reduce the load on continuous fibers placed in the mixture and increase the accuracy of regulation of laying due to the tension of the fibers. In addition, the final cured product has a higher strength in accordance with the equation of strength. Although the mixtures of Examples 54-57 do not provide shape stability after extrusion, the mixtures of Examples 58-65 can be extruded to produce a variety of products, including those listed above. And finally, the mixtures of examples 66 and 67 are too dry and viscous, which does not allow their extrusion using existing equipment. An increase in the packing density of the particles also improves the fixation of continuous fibers in the cured product molded from such mixtures, since this increases the contact area of the fibers with other components of the hydraulically settable structural matrix.

Examples 68-79
The hydraulically settable mixtures of Examples 25 to 36 are altered by reducing the mass of silica sand to 4 kg and adding 2 kg of precipitated calcium carbonate with an average particle size of about 1 μm. The packing density of the particles of the resulting hydraulically settable mixture is about 0.8. In the table. 5 shows the values of water scarcity obtained with a given mass of water.

 As in the above examples, maintaining a constant volume of water while increasing the packing density of the particles allows us to obtain a hydraulically settable mixture that can be extruded at lower pressure, which can reduce the load on continuous fibers placed in the mixture and increase the accuracy of regulation of laying due to the tension of the fibers. In addition, the final cured extruded product has a higher strength in accordance with the equation of strength.

 An increase in the packing density of the particles also improves the fixation of continuous fibers in the cured product molded from such mixtures, since this increases the contact area of the fibers with other components of the hydraulically settable structural matrix.

Examples 80 - 89
The hydraulically settable mixtures of Examples 44-53 are altered by reducing the mass of silica sand to 4 kg and adding 2 kg of precipitated calcium carbonate with an average particle size of about 1 μm. The packing density of the particles of the resulting hydraulically settable mixture is about 0.85. In the table. 6 shows the values of water scarcity obtained with a given mass of water.

 As in the above examples, maintaining a constant volume of water while increasing the packing density of the particles allows us to obtain a hydraulically settable mixture that can be extruded at lower pressure, which can reduce the load on continuous fibers placed in the mixture and increase the accuracy of regulation of laying due to the tension of the fibers. In addition, the final cured extruded product has a higher strength in accordance with the equation of strength.

 An increase in the packing density of the particles also improves the fixation of continuous fibers in the cured product molded from such mixtures, since this increases the contact area of the fibers with other components of the hydraulically settable structural matrix.

Examples 90 to 95
The hydraulically settable mixtures of Examples 62 to 67 are altered by reducing the mass of silica sand to 4 kg and adding 2 kg of precipitated calcium carbonate with an average particle size of about 1 μm. The packing density of the particles of the resulting hydraulically settable mixture is about 0.9. In the table. 7 shows the values of water scarcity obtained with a given mass of water.

 As in the above examples, maintaining a constant volume of water while increasing the packing density of the particles allows us to obtain a hydraulically settable mixture that can be extruded at lower pressure, which can reduce the load on continuous fibers placed in the mixture and increase the accuracy of regulation of laying due to the tension of the fibers. In addition, the final cured extruded product has a higher strength in accordance with the equation of strength.

 An increase in the packing density of the particles also improves the fixation of continuous fibers in the cured product molded from such mixtures, since this increases the contact area of the fibers with other components of the hydraulically settable structural matrix.

Example 96
The operations of Examples 1 to 9 are repeated with the exception that the average particle size is reduced while maintaining the same level of particle packing density and water deficiency. The resulting hydraulically settable mixtures exhibit enhanced pseudoplasticity. In other words, the apparent viscosity of mixtures with a smaller average particle size at a given shear level decreases, and the yield strength increases. This allows you to get a mixture that can be extruded at a lower pressure, but which will demonstrate a higher dimensional stability. Extrusion under reduced pressure can reduce the load on the continuous fibers placed in the mixture and increase the accuracy of regulation of laying due to the tension of the fibers. The shape stability of such mixtures is significantly increased due to the continuous fibers placed in the mixtures.

Example 97
The operations of examples 90 to 95 are repeated, except that the extruded products are cured by autoclaving at a temperature of 400 ^° C. and a pressure of 24 atm for 12 hours. The final cured products have a compressive strength of about 800 MPa and a tensile strength of about 100 MPa. The tensile strength of the final cured products is significantly increased due to the fibers placed in the mixture.

Example 98
The operations of Examples 1 - 9 are repeated, except that the mixture was added 25 g of Tylose ^® 4000 reagent as a lubricant. The obtained hydraulically settable mixtures have a high fluidity, which ensures the production of extruded products with a higher surface quality and without a significant reduction in the pulling force of the fibers into the mixture. Strength characteristics are practically unchanged.

Example 99
The operations of examples 1 to 9 are repeated, except that 25 g of calcium or magnesium stearate is added to the mixture as a lubricant. The obtained hydraulically settable mixtures have a high fluidity, which ensures the production of extruded products with a higher surface quality and without a significant reduction in the pulling force of the fibers into the mixture. Strength characteristics are practically unchanged.

Example 100
The operations of examples 1 to 9 are repeated, except that 25 g of polyethylene glycol with an average molecular weight of about 35,000 is added to the mixture as a lubricant. The obtained hydraulically settable mixtures have increased fluidity, which ensures the production of extruded products with higher surface quality and without significant reduce the strength of the fibers in the mixture. Strength characteristics are practically unchanged.

Example 101
An extrudable hydraulically settable mixture is prepared containing the following components:
Fly Ash - 90 g
Portland cement - 10 g
NaOH - 10 g
Water - 20 g
Sodium hydroxide increases the pH of the aqueous phase of the hydraulically settable mixture to about 14, which activates fly ash so that it acts as a hydraulically settable binder. Portland cement is added to increase the compressive strength of the final cured product to about 20 MPa and tensile strength to about 105 MPa. Due to the low cost of fly ash, the mixture according to this example is cheaper than mixtures with a high concentration of Portland cement and conventional aggregates. Of course, in cases where lower strength is allowed, Portland cement can be added in an even smaller volume or not at all. Fly ash also increases frictional contact with continuous fibers, which increases the pulling power of the fibers with the mixture and improves the fastening of the continuous fibers within the hydraulically settable matrix.

Example 102
An extrudable hydraulically settable mixture is prepared containing the following components:
White Portland Cement - 4.0 kg
Fine sand - 6.0 kg
Water - 1.5 kg
Tylose ^® FL 15002 - 200 g
A hydraulically settable mixture is formed by mixing the ingredients for 10 minutes in a high speed mixer to obtain a very uniform mixture. After that, the mixture is used for the extrusion of various multi-cell products, including “honeycomb” structures with very high compressive strength, especially considering the presence of open cells in the extruded product.

Due to its multicellular structure, the cured material has a much lower mass than comparable whole extruded objects made from the same hydraulically settable mixtures. The bulk density of multi-cell structures is only 1.02 g / cm ³ . In addition, extruded materials have a compressive strength of about 75 MPa and a tensile strength of about 28 MPa. Depending on the volume of voids inside the multicell structure, it is easy to provide bulk density with any values in the range of about 0.5 g / cm ³ to 1.6 g / cm ³ . The tensile strength can be significantly increased by laying in a mixture of continuous fibers, which will further reduce bulk density.

Examples 103 to 105
Extrudable hydraulically settable mixtures are prepared according to Example 102, except that (short) hemp fibers in various concentrations (by volume) are added to the mixture:
Example - Hemp fiber
103 - 1%
104 - 2%
105 - 3%
The obtained extruded multi-cell structures have higher strengths, both in the wet state and after curing, in comparison with the structures of Example 102. In addition, the multi-cell structures molded in these examples are more ductile and less brittle, especially with increasing fiber concentration in a hydraulically settable mixture. Laying in a mixture of continuous fibers further increases ductility and reduces the fragility of structures.

Examples 106 to 108
The extrudable hydraulically settable mixtures are prepared according to Example 102, except that (short) glass fibers in various concentrations (by volume) are added to the mixture:
Example - Fiberglass
106 - 1%
107 - 2%
108 - 3%
The obtained extruded multi-cell structures have higher strengths, both in the wet state and after curing, in comparison with the structures of Example 102. In addition, the multi-cell structures molded in these examples are more ductile and less brittle, especially with increasing fiber concentration in a hydraulically settable mixture. Similarly, laying in a mixture of continuous fibers significantly increases ductility and reduces the fragility of structures.

 The following examples demonstrate how the strength of an extrudable hydraulically settable mixture increases or decreases with changes in the following variables: particle packing density, water to cement ratio, and cement concentration as a percentage of the mass of solids in the mixture.

Examples 109 - 114
Extrudable hydraulically settable mixtures are prepared containing 1.0 kg of Portland cement and 6.0 kg of sand. In each mixture, the concentration of Portland cement is 14.3% by weight of the dry mixture. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount of water added to the mixture also varies to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50%.

 As will be shown, the compressive strength of a hydraulically settable mixture with a constant weight concentration of Portland cement and sand increases if: (1) the particle packing density increases while maintaining a constant degree of water deficiency, or (2) the degree of water deficiency increases while maintaining a constant packing density particles. The amount of water is expressed in kg and the compressive strength in MPa. The term "W / C" is an abbreviation for the ratio of the concentrations of water and cement.

 Examples in the table. 8 clearly show that the strength of the extrudable product will increase significantly with increasing packing density of the particles, even while maintaining absolute values of the concentration of cement and sand. This corresponds to the strength equation, since with an increase in the packing density of particles, the volume of air and water in the mixture decreases. However, by maintaining a constant degree of water deficiency, the mixtures have approximately the same workability and can be extruded at approximately the same pressure. Increasing the packing density of the particles improves the frictional contact between the continuous fibers and other components of the hydraulically settable structural matrix, which increases the pulling force of the fibers with the mixture and improves the fixation of continuous fibers inside the hydraulically settable matrix.

Examples 115 to 120
The compositions of examples 109 - 114 are basically repeated, with the exception that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see table. 9).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 121 to 126
The compositions of examples 109 - 114 are basically repeated, with the exception that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 10).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 127 to 132
The compositions of examples 109 - 114 are mainly repeated, with the exception that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table. 11).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 133 to 138
The compositions of examples 109 - 114 are basically repeated, with the exception that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table. 12).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. A comparison of the results obtained in examples 109 - 138, demonstrates the close relationship between strength and absolute water content in a hydraulically settable mixture. This clearly shows that to simultaneously ensure high strength and good workability of this mixture, it is advisable to increase the packing density of the particles instead of increasing the concentration of water to increase the fluidity of the mixture under pressure.

 The following series of examples is basically similar to examples 109 - 138, with the exception that the concentration of Portland cement increases to 25% by weight of dry mixes. These examples allow us to demonstrate that an increase in the concentration of a hydraulically settable binder results in only a small increase in strength, while a much more substantial increase in strength is achieved by increasing the packing density of the particles and reducing the concentration of water in the mixtures.

Examples 139 to 144
Extrudable hydraulically settable mixtures are prepared containing 2.0 kg of Portland cement and 6.0 kg of sand. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount of water added to the mixture also varies to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50% (see table 13).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 145 to 150
The compositions of Examples 138-139 are generally repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see Table 14).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 151 to 156
The compositions of examples 138 - 139 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 15).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 157 to 162
The compositions of examples 138 - 139 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table. 16).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 163 - 168
The compositions of examples 138 - 139 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table 17).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. A comparison of the results obtained in examples 139 - 168, demonstrates the close relationship between strength and absolute water content in a hydraulically settable mixture. Although the increase in the concentration of Portland cement in the mixtures according to Examples 139–168 leads to an increase in the overall strength of the mixtures, this increase is less significant than in the case of an increase in the packing density of particles and a decrease in the concentration of water in the mixtures.

 The following series of examples is basically similar to examples 139 - 168, with the exception that the concentration of Portland cement increases to 33% by weight of dry mixes.

Examples 169 to 174
Extrudable hydraulically settable mixtures are prepared containing 3.0 kg of Portland cement and 6.0 kg of sand. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount of water added to the mixture also varies to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50% (see table 18).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 175 - 180
The compositions of examples 169-174 are basically repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see table. 19).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 181 to 186
The compositions of examples 169 - 174 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 20).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 187 to 192
The compositions of examples 169 - 174 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table. 21).

 The compressive strength of a hydraulically settable mixture increases as the water concentration decreases. An increase in compressive strength by lowering the concentration of water may be useful in counteracting a tendency toward a decrease in compressive strength of the final cured article when continuous fibers are introduced.

Examples 193 to 198
The compositions of examples 169 - 174 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table. 22).

 Comparison of the strength of different compositions according to examples 169 -198 depending on the packing density of the particles demonstrates the close relationship between the strength and the absolute water content in the hydraulically settable mixture. Although an increase in the concentration of Portland cement in the mixtures of Examples 169 to 198 causes an increase in the overall strength of the mixtures, such an increase is less significant than in the case of an increase in the packing density of particles and a decrease in the concentration of water in the mixtures.

 The following series of examples is basically similar to examples 169 - 198, with the exception that the concentration of Portland cement increases to 40% by weight of dry mixes.

Examples 199 - 204
Extrudable hydraulically settable mixtures are prepared containing 4.0 kg of Portland cement and 6.0 kg of sand. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount added to the mixture also varies.
water to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50% (see table 23).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 205 to 210
The compositions according to examples 199 - 204 are basically repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see table 24).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 211 to 216
The compositions according to examples 199 - 204 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 25).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 217 to 222
The compositions according to examples 199 - 204 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table. 26).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 223 to 228
The compositions according to examples 199 - 204 are mainly repeated, with the exception that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table. 27).

 Comparison of the strength of different compositions according to examples 199 - 228 depending on the packing density of particles demonstrates the close relationship between strength and the absolute water content in a hydraulically settable mixture. Although the increase in the concentration of Portland cement in the mixtures according to Examples 199 - 228 causes an increase in the overall strength of the mixtures, such an increase is less significant than in the case of an increase in the packing density of particles and a decrease in the concentration of water in the mixtures.

 The following series of examples is basically similar to examples 199 - 228, with the exception that the concentration of Portland cement increases to 45.5% by weight of dry mixes.

Examples 229 to 234
Extrudable hydraulically settable mixtures are prepared containing 5.0 kg of Portland cement and 6.0 kg of sand. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount of water added to the mixture also varies to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50% (see table 28).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 235 - 240
The compositions of examples 229 - 234 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see table. 29).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 241 to 246
The compositions of examples 229 - 234 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 30).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 247 - 252
The compositions of examples 229 - 234 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table. 31).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 253 - 258
The compositions of examples 229 - 234 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table 32).

 Comparison of the strength of different compositions according to examples 229 - 258 depending on the packing density of particles demonstrates the close relationship between strength and the absolute water content in a hydraulically settable mixture. Although the increase in the concentration of Portland cement in the mixtures according to Examples 229 - 258 causes an increase in the overall strength of the mixtures, such an increase is less significant than in the case of an increase in the packing density of particles and a decrease in the concentration of water in the mixtures.

 The following series of examples is basically similar to examples 229 - 258, with the exception that the concentration of Portland cement increases to 50% by weight of dry mixes.

Examples 259 - 264
Extrudable hydraulically settable mixtures are prepared containing 6.0 kg of Portland cement and 6.0 kg of sand. The particle sizes of the sand vary to obtain mixtures with a packing density of particles in the range from 0.65 to 0.90 in increments of 0.05. In addition, the amount of water added to the mixture also varies to obtain mixtures with the desired degree of water deficiency. In this first series of examples, the water deficit is 50% (see table 33).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 265 - 270
The compositions of examples 259 - 264 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 60% (see table. 34).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 271 to 276
The compositions of examples 259 - 264 are mainly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 70% (see table. 35).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 277 - 282
The compositions of examples 259 - 264 are basically repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 80% (see table 35A).

 The compressive strength of a hydraulically settable mixture increases as particle packing density increases and water concentration decreases. Increasing the compressive strength by increasing the packing density of the particles and lowering the concentration of water may be useful in counteracting the tendency for the compressive strength of the final cured article to decrease when continuous fibers are introduced.

Examples 283 to 288
The compositions of examples 259 - 264 are mostly repeated, except that the water concentration in each example is reduced so that the degree of water deficiency is 90% (see table. 36).

 Comparison of the strength of different compositions according to examples 259 - 288 depending on the packing density of particles demonstrates the close relationship between strength and the absolute water content in a hydraulically settable mixture. Although an increase in the concentration of Portland cement in the mixtures of Examples 259–288 causes an increase in the overall strength of the mixtures, this increase is less significant than in the case of an increase in the packing density of particles and a decrease in the concentration of water in the mixtures.

 The following group of examples illustrates the effect of the natural packing density of particles of sand and Portland cement on the total packing density of particles of a two-component system (i.e., a system consisting of Portland cement and sand). The application of the information given in these examples will allow the average person skilled in the art to develop compositions of hydraulically settable mixtures in which the particle packing densities will correspond to those given in Examples 109-28 above. As shown below, the resulting particle packing density depends not only on the values of natural packing densities of cement and sand particles, but also on the average particle diameter of cement and sand, respectively.

 It should be noted that different sand-based aggregates can have the same average diameter and, at the same time, significantly different particle densities. The natural packing density of the aggregate with a given particle diameter will increase or decrease depending on the distribution of particle diameters relative to the average diameter. As a rule, the larger the dispersion of particle sizes, the higher the natural packing density of the particles of a given aggregate material.

Examples 289 to 294
Hydraulically settable mixtures are prepared containing 1.0 kg of Portland cement and 6.0 kg of sand, so that the mixtures contain 14.3% cement and 85.7% sand aggregate based on the weight of dry components. Portland cement is composed of particles with an average size of 15 microns and a natural packing density of 0.580. To obtain the desired total packing density of the particles of the mixture, five different types of sand aggregate are selected, divided into categories depending on the average particle diameter. Five different aggregates, which are called “aggregate 1”, “aggregate 2”, etc., are composed of particles with an average size of 0.1 mm, 0.2 mm, 0.5 mm, 1.0 mm and 1.25 mm, respectively.

 Each of the five types of sand aggregate is further subdivided based on the natural packing density of the particles, as described below. In the table. Figure 37 illustrates the change in the overall particle packing density as a result of mixing with the above Portland cement five different types of aggregate with different particle packing densities. The term “placeholder” is abbreviated as “App.”; the total packing density is abbreviated as “Density.” and the numbers given in each column with the name “Zap.” represent the natural packing density of the particles of this aggregate (see table 37).

 As can be seen from these examples, an increase in the overall packing density of the particles can be achieved by maintaining a constant average particle size of the aggregate particles while increasing the natural packing density of the aggregate particles or by maintaining a constant natural packing density of the aggregate particles when increasing the average particle size of the aggregate. In the latter case, an increase in particle packing density is caused by an increase in the spread between the average aggregate particle sizes and the cement particle size. However, it seems that a change in the natural packing density of the particles of this aggregate material provides a more significant increase in the overall packing density of the particles. An increase in the packing density of particles leads to an increase in the area of frictional contact with continuous fibers and other components of a hydraulically settable structural matrix, which increases the pulling force of continuous fibers placed in a mixture and also improves the fixing of such fibers inside a hydraulically settable structural matrix.

Examples 295 to 298
The compositions, methods and prerequisites specified in examples 289 to 294 are completely repeated, except that hydraulically settable mixtures contain 2.0 kg of Portland cement and 6.0 kg of sand aggregate, which makes it possible to obtain mixtures containing 25% cement and 75% sand aggregate by weight of dry components. The average particle sizes of Portland cement and five different types of sand aggregate in the following examples correspond to those indicated in examples 289 - 294 (see table 38).

 These examples show that as Portland cement concentration increases, it becomes more difficult to formulate mixtures from two-component systems that would have a high overall particle packing density. This is due to the general uniformity (reduction in size dispersion) of the particles of Portland cement in comparison with the particles of sand aggregate. Reducing the dispersion of particle sizes usually does not allow for a higher packing density of particles.

Examples 299-302
The compositions, methods and prerequisites specified in examples 289 to 294 are completely repeated, except that hydraulically settable mixtures contain 3.0 kg of Portland cement and 6.0 kg of sand aggregate, which makes it possible to obtain mixtures containing 33.3% cement and 66.7% of sand aggregate by weight of dry components. The average particle sizes of Portland cement and five different types of sand aggregate in the following examples correspond to those indicated in examples 289 - 294 (see table. 39).

Examples 303-305
The compositions, methods and prerequisites specified in examples 289 to 294 are completely repeated, except that hydraulically settable mixtures contain 4.0 kg of Portland cement and 6.0 kg of sand aggregate, which makes it possible to obtain mixtures containing 40% cement and 60% of sand aggregate by weight of dry components. The average particle sizes of Portland cement and five different types of sand aggregate in the following examples correspond to those indicated in examples 289 - 294 (see table. 40).

Examples 306-308
The compositions, methods and prerequisites specified in examples 289 to 294 are completely repeated, except that hydraulically settable mixtures contain 5.0 kg of Portland cement and 6.0 kg of sand aggregate, which makes it possible to obtain mixtures containing 45.5% cement and 54.5% of sand aggregate by weight of dry components. The average particle sizes of Portland cement and five different types of sand aggregate in the following examples correspond to those indicated in examples 289 - 294 (see table 41).

Examples 309 - 310
The compositions, methods and prerequisites specified in examples 289 to 294 are completely repeated, except that hydraulically settable mixtures contain 6.0 kg of Portland cement and 6.0 kg of sand aggregate, which makes it possible to obtain mixtures containing 50% cement and 50% sand aggregate by weight of dry components. The average particle sizes of Portland cement and five different types of sand aggregate in the following examples correspond to those indicated in examples 289-294 (see table. 42).

Examples 311 to 316
Hydraulically curable products with spiral winding of continuous fibers were made using the usual methods of winding continuous fibers (i.e., the crude hydraulically settable mixture was shaped like a pipe wrapped around a mandrel, after which the fibers were wound around and inside the mixture). The percentage concentration of fibers wound inside and inside hydraulically settable products gradually increased, while the winding angle was kept constant at 45 ^° to determine the effect of fiber concentration on the strength of products with wound fibers on pressure rupture. As shown below, the initially introduced fibers at a concentration of 3.0% resulted in a sharp increase in tensile strength under pressure (in the Tear tables). After that, with a further increase in the fiber concentration, the tensile strength under pressure continued to increase, but not so significantly (see Table 43).

 The dependence of the tensile strength under pressure for each product on the angle of winding of the fibers around the hydraulically settable structural matrix is shown in graphical form in FIG. thirty.

 In view of the foregoing, it can be expected that products molded using the methods and devices of the present invention, along with similar blend compositions and fiber concentrations, will have the same or even higher tensile strength under pressure compared to products molded using conventional methods of winding continuous fibers. It can be expected that the tensile strength under pressure of the products molded according to the present invention will be higher due to improved contact between the fibers and the hydraulically settable structural matrix, which is due to improved compaction, consolidation and reduced porosity of the extrudable mixture. In addition, it is expected that as a result of extrusion, a significant increase in the surface quality of the products will be ensured.

Examples 317 to 319
Hydraulically curable products with spiral winding of continuous fibers were made using conventional methods of winding continuous fibers, indicated in examples 311 - 316. However, the percentage concentration of fibers was maintained at 3.0%, while the angle of winding was changed to 35 ^o , 45 ^o and 65 ^o , respectively, to demonstrate the effect of the winding angle on the strength of products with wound fibers on tensile under pressure. As shown below, as the angle of winding of the fibers increased, the tensile strength under pressure increased significantly (see Table 44).

 The dependence of the tensile strength under pressure for products on the angle of winding of the fibers around the hydraulically settable structural matrix is shown in graphical form in FIG. 31.

 In view of the foregoing, it can be expected that products molded using the methods and devices of the present invention, along with similar blend compositions and fiber concentrations, will have the same or even higher tensile strength under pressure compared to products molded using conventional methods of winding continuous fibers. It can be expected that the tensile strength under pressure of products molded according to the present invention will be higher due to improved contact between the fibers and the hydraulically settable structural matrix, which is due to improved compaction, consolidation and reduced porosity of the extrudable mixture. In addition, it is expected that as a result of extrusion, a significant increase in the surface quality of the products will be ensured.

Examples 320 - 324
Hydraulically curable products with spiral winding of continuous fibers were made using the usual methods of winding continuous fibers, described in examples 311 - 316. The percentage concentration of fibers wound inside the hydraulically cured products and inside them was gradually increased, while the angle of winding α was kept constant at 45 ^o to determine the effect of the concentration of fibers on the modulus of elasticity of products with wound fibers. As indicated below, the modulus of elasticity steadily and significantly increased with increasing percentage concentration of fibers (see table. 45).

 In FIG. 32 shows in graphical form the dependence of the elastic modulus on the percentage concentration of fibers around and inside the hydraulically settable structural matrix of each product.

 In view of the foregoing, it can be expected that products molded using the methods and devices of the present invention, along with similar mixture compositions and fiber concentrations, will have the same or even higher modulus of elasticity compared to products molded using conventional winding methods continuous fibers. It can be expected that the elastic modulus of the products molded according to the present invention will be higher due to improved contact between the fibers and the hydraulically settable structural matrix, which is due to improved compaction, consolidation and reduced porosity of the extrudable mixture. In addition, it is expected that as a result of extrusion, a significant increase in the surface quality of the products will be ensured.

Examples 325 to 329
Hydraulically curable products with spiral winding of continuous fibers were made using the usual methods of winding continuous fibers, indicated in examples 311 - 316. However, the percentage concentration of fibers was maintained at 3.0%, while the angle of winding was changed to 35 ^o , 45 ^o , 55 ^o , 65 ^o and 75 ^o , respectively, to demonstrate the influence of the angle of winding on the modulus of elasticity of products with wound fibers. As shown below, the modulus of elasticity of products sharply increased as the angle of winding of the fibers increased to about 65 ^o , after which, with an increase in the angle of winding to 75 ^{o, the} increase in the modulus of elasticity was not so sharp, but still significant (see table 46).

 In FIG. 33 graphically shows the dependence of the elastic modulus on the angle of winding of the fibers around and inside the hydraulically settable structural matrix of each product.

 In view of the foregoing, it can be expected that products molded using the methods and devices of the present invention, along with similar mixture compositions and fiber concentrations, will have the same or even higher modulus of elasticity compared to products molded using conventional winding methods continuous fibers. It can be expected that the elastic modulus of the products molded according to the present invention will be higher due to improved contact between the fibers and the hydraulically settable structural matrix, which is due to improved compaction, consolidation and reduced porosity of the extrudable mixture. In addition, it is expected that as a result of extrusion, a significant increase in the surface quality of the products will be ensured.

V. Consolidated Review
From the foregoing, it is clear that the compositions, methods and devices of the present invention provide the ability to simultaneously lay continuous fibers during the extrusion of hydraulically settable materials to give them the shape of products and profiles, the preparation of which was previously impossible due to the strength and technological limitations inherent in hydraulically settable compositions, famous at present.

 In addition, the present invention provides compositions, methods and devices for extruding and stacking continuous fibers in hydraulically settable products in which the ratio of tensile strength and compressive strength is increased compared to traditional hydraulically settable materials.

 Further, the present invention provides compositions, methods and devices that enable continuous extrusion of a hydraulically settable mixture with simultaneous laying of continuous fibers so that the extruded products or profiles immediately acquire shape stability (i.e., sufficient strength to maintain their shape without external support) in wet condition after exiting the extrusion die.

 The present invention also provides compositions, methods and devices that enable continuous laying into an extrudable hydraulically settable mixture of continuous fibers in a wide variety of concentrations.

 In addition, the present invention also provides the possibility of laying in a hydraulically settable mixture of continuous fibers with a different orientation or at different angles relative to the longitudinal axis of the extrudable product.

 Further, the present invention also provides compositions, methods and devices that provide extrusion of form-resistant pipes and cylinders with significantly increased tensile strength under the influence of internal or external pressure.

 The present invention also provides compositions, methods and devices that result in efficient consolidation or densification of a hydraulically settable mixture around and between continuously stacked fibers, thereby minimizing the number and volume of internal voids or defects, and thereby obtaining a cured hydraulically settable structural a matrix that will have a substantially uniform structure and uniform high strength.

 In addition, the present invention also provides compositions, methods and devices that allow the extrusion of hydraulically settable products with continuously laid fibers, which have a significantly higher surface quality with a significant reduction in the concentration of surface defects in comparison with known methods for manufacturing cemented materials with wound fibers.

 The present invention also provides such compositions, methods and devices that are used to obtain a variety of thin-walled hydraulically settable products, including products with very tight tolerances or exact dimensions.

 The present invention also provides such compositions, methods and devices that are used to extrude hydraulically settable continuous fiber-laid products that can replace products currently made from traditional materials such as plastic, clay, metal or wood.

 In addition, the present invention provides hydraulically settable compositions in which the rheological characteristics and ductility are similar to those of clay, which will allow the extrusion of such compositions using extruders designed for clay.

 Finally, the present invention also provides such compositions, methods and devices that can be used for the continuous manufacture of a variety of hydraulically settable products at such a cost of mass production (i.e., manufacturing in large volumes or quantities) that is comparable to the cost of manufacturing such products from plastic, clay, metal or wood, or even will be below this cost.

 The present invention can be implemented in other specific forms without deviating from its essence or basic characteristics. The described embodiments in all respects are illustrative and not limiting the scope of the invention. Therefore, the scope of the invention is determined by the attached patent claims, and not the above description. All changes within the meaning and range of equivalence of the patent claims are within the scope of the invention.

Claims (79)

 1. A method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, a filler material, a rheological agent, and water in relative concentrations to produce a hydraulically settable mixture having fluidity during extrusion under pressure through a die and immediately acquires stability after exiting the die, extrusion of a hydraulically settable mixture under pressure through the die with simultaneous irregularly laying fibers in said mixture and curing the extruded hydraulically settable mixture to form a hydraulically settable matrix for an industrial product, characterized in that when laying the fibers in a hydraulically settable mixture, continuous and simultaneous winding of at least one fiber to produce the product is carried out containing at least one wound fiber, and using styling means made with the possibility of direct input and simultaneous continuous winding of one or a series of fibers into a hydraulically settable mixture with different depths, winding angles and fiber concentrations inside the product.  2. The method according to claim 1, characterized in that the die has a longitudinal axis, and the laying operation gives an article containing fiber having a substantially parallel orientation relative to the longitudinal axis of the die. 3. The method according to claim 1, characterized in that the die has a longitudinal axis, and the laying operation includes winding at least one fiber in a hydraulically settable mixture, wherein the winding angle exceeds about 5 ^° relative to the longitudinal axis of the die, preferably more more than about 35 ^° relative to the longitudinal axis of the die, more preferably more than about 50 ^° relative to the longitudinal axis of the die, especially more than about 75 ^° relative to the longitudinal axis of the die. 4. The method according to claim 1, characterized in that the die has a longitudinal axis, and the laying operation allows to obtain an article containing a fiber having a substantially parallel orientation and including another fiber wound at an angle exceeding about 5 ^° relative to the longitudinal the axis of the die.  5. The method according to claim 1, characterized in that the hydraulically settable binder contains Portland cement. 6. A method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, a filler material and water in relative concentrations to obtain a hydraulically settable mixture having fluidity during extrusion under pressure through a die and immediately gaining form stability after exiting the die, extrusion a hydraulically settable mixture under pressure through a die having a longitudinal axis and an inside through which the mixture passes through walks during extrusion with the formation of an extruded product, the continuous laying of fibers in the specified mixture when it is extruded through a die, and the curing of the extruded hydraulically settable mixture to form a hydraulically settable matrix for an industrial product, characterized in that when laying the fibers in a hydraulically settable mixture continuous and simultaneous winding by means of laying at least one fiber to obtain an article comprising at least , one fiber having a winding angle of at least 5 ^o relative to the longitudinal axis, using styling means configured to directly enter and simultaneously wind at least one fiber wound during insertion with different winding angles, at least , 5 ^o relative to the longitudinal axis, with different depths and fiber concentrations inside the hydraulically settable mixture.  7. The method according to claim 1 or 6, characterized in that the mixing is performed, at least in part, by means of a mixer with a large shear.  8. The method according to claim 1 or 6, characterized in that the hydraulically settable binder and the filler material consist of individual particles in which the natural packing density is in the range from about 0.65 to 0.99, preferably from about 0, 75 to 0.9.  9. The method according to claim 1 or 6, characterized in that the hydraulically settable binder contains hydraulic cement, preferably selected from the group of materials including Portland cement, especially fine-grained cement, slag cement, calcium aluminate cement, plaster, silicate cement , gypsum cement, phosphate cement, white cement, high alumina cement, cement based on magnesium oxychloride, aggregates coated with particles of especially fine-grained cement, as well as mixtures and derivatives of decree OF DATA materials.  10. The method according to claim 1 or 6, characterized in that the hydraulically settable binder contains fly ash activated by a strong alkali.  11. The method according to claim 1 or 6, characterized in that the mixing of the components includes the addition of fibrous material in a hydraulically settable mixture.  12. The method of extrusion of a hydraulically settable mixture according to claim 11, characterized in that the fibrous material contains cellulosic fibers, preferably at least one of the following: cotton, bagasse, hemp, hemp, sisal, wood fiber, as well as mixtures and derivatives thereof materials.  13. The method according to claim 11, characterized in that the fibrous material contains fibers selected from at least one of the following: ceramic fibers, fiberglass, carbon fibers, metal fibers, organic polymer fibers, as well as mixtures and derivatives thereof.  14. The method according to claim 11, characterized in that the concentration of fibrous material is from about 0.5 to 30% by volume of the hydraulically settable mixture, preferably from about 1 to 20% of the volume of hydraulically settable mixture.  15. The method according to claim 6, characterized in that the mixing of the components includes the addition of changing the rheological characteristics of the substance, preferably in the range from about 0.1 to 5% by weight of the hydraulically settable mixture with the exception of water, especially in the range from about 0.5 up to 1% by weight of a hydraulically settable mixture with the exception of water.  16. The method according to claim 1 or 15, characterized in that the rheological characteristics of the substance contains cellulose-based material or its derivative, preferably containing one of the following: methylhydroxyethyl cellulose, hydroxymethyl cellulose, carboxymethyl cellulose, methyl cellulose, ethyl cellulose, hydroxyethyl cellulose, hydroxypropyl methyl cellulose, hydroxy also mixtures and derivatives thereof.  17. The method according to claim 1 or 15, characterized in that changing the rheological characteristics of the substance contains a material based on starch or its derivative, preferably containing one of the following: amylopectin, amylose, sea gel, starch acetates, hydroxyethyl starch ethers, ionic starches, extended molecular chain alkyl starches, dextrins, amine starches, phosphate starches, dialdehyde starches, as well as mixtures and derivatives thereof.  18. The method according to claim 1 or 15, characterized in that changing the rheological characteristics of the substance contains a material based on protein and its derivative, preferably containing at least one of the following: prolamine, collagen derivatives, gelatin, glue, casein, and mixtures and derivatives thereof.  19. The method according to clause 15, wherein the rheological characteristics of the substance contains a synthetic organic material, preferably containing at least one of the following: polyvinylpyrrolidone, polyethylene glycol, polyvinyl alcohol, polyvinyl methyl ether, polyacrylic acids, salts of polyacrylic acids, polyvinyl acrylic acids , salts of polyvinylacrylic acids, polylactic acid, polyacrylamides, ethylene oxide polymers, latex, as well as mixtures and derivatives thereof.  20. The method according to claim 1 or 15, characterized in that the rheological changing substance is selected from at least one of the following: alginic acid, phycocolloids, agar, gum arabic resin, gaura resin, robinia bean resin, karaya resin, tragacanth resin, as well as mixtures and derivatives thereof.  21. The method according to claim 1 or 6, characterized in that the mixing of the components includes adding a dispersant to the hydraulically settable mixture containing preferably at least one of the following: sulfonated condensate of naphthalene-formaldehyde, sulfonated condensate of melamine-formaldehyde, lignosulfonate, acrylic acid, as well as their salts, mixtures and derivatives.  22. The method according to p. 1 or 6, characterized in that the aggregate material includes at least one of the following: clay, gravel, sand, alumina, silica sand, fused silica, micrograin silica, fly ash, crushed limestone , crushed sandstone, crushed granite, crushed basalt, crushed bauxite, as well as mixtures thereof.  23. The method according to claim 1 or 6, characterized in that the concentration of the filler material is in the range from about 3 to 90% by weight of the hydraulically settable mixture, preferably from about 20 to 70% by weight of the hydraulically settable mixture.  24. The method according to claim 1 or 6, characterized in that in the hydraulically settable mixture, the initial net water deficiency is preferably more than about 10%, more preferably more than about 25%, especially more than about 50%.  25. The method according to claim 1 or 6, characterized in that the extrusion is carried out using at least a screw extruder or a piston extruder.  26. The method according to claim 1 or 6, characterized in that the extrusion includes placing a hydraulically settable mixture in a rarefied atmosphere to remove air from the mixture.  27. The method according to claim 1 or 6, characterized in that the extrusion pressure is in the range from about 10 to 7000 bar, preferably from about 20 to 3000 bar, especially from about 50 to 200 bar.  28. The method according to claim 1 or 6, characterized in that the extrusion involves forming a hydraulically settable mixture in the form of a hollow product.  29. The method according to p, characterized in that the die includes a hollow inner part and a mandrel located in it, designed to form a hollow product. 30. The method according to p, characterized in that the density of the hollow product is up to about 1.5 g / cm ³ , preferably up to about 0.3 g / cm ³ . 31. The method according to p. 28, characterized in that the tensile strength of the hardened hydraulically settable matrix of a hollow industrial product exceeds about 10 N / mm ² , preferably more than about 30 N / mm ² , especially more than about 50 N / mm ² .  32. The method according to claim 1 or 6, characterized in that the laying of the fibers is carried out in an amount in the range of from about 0.5 to 30% of the volume of the hydraulically settable mixture, preferably in the range of from about 1 to 20% of the volume of the hydraulically settable mixture, especially in the range of about 2 to 10% of the volume of the hydraulically settable mixture.  33. The method according to p. 1 or 6, characterized in that the fiber is selected from at least one of the following: glass fiber, polyaramide fibers, graphite fibers, carbon fibers, polyethylene fibers, as well as mixtures and derivatives thereof.  34. The method according to claim 1 or 6, characterized in that the fiber includes many connected together individual fibers. 35. The method according to claim 1 or 6, characterized in that the laying operation allows you to obtain a product in which the value of the angle of winding of the fibers exceeds about 20 ^o relative to the longitudinal axis of the die, preferably exceeds about 45 ^o relative to the longitudinal axis of the die, more preferably exceeds about 65 ^o relative to the longitudinal axis of the die, especially greater than about 85 ^o relative to the longitudinal axis of the die. 36. The method according to claim 6, characterized in that the laying operation allows you to obtain a product in which at least one fiber has a winding angle of approximately less than 5 ^o relative to the longitudinal axis of the die in addition to at least one fiber whose winding angle exceeds approximately more than 5 ^o relative to the longitudinal axis of the die.  37. The method according to claim 1 or 6, characterized in that the stacking operation allows to obtain an article containing winding fibers made of different materials.  38. The method according to claim 1 or 6, characterized in that the laying operation allows you to get a product in which at least two fibers are cross-oriented.  39. The method according to claim 1 or 6, characterized in that during the laying operation, the fiber is wound at a predetermined peripheral speed to obtain an article with the desired fiber winding angle.  40. The method according to claim 1 or 6, characterized in that the extrusion of the hydraulically settable mixture is carried out at a given speed to obtain the product with the desired angle of winding of the fiber.  41. The method according to p. 1 or 6, characterized in that the laying of a certain number of fibers in a hydraulically settable mixture is carried out with the possibility of obtaining products having the desired concentration of fibers, preferably at least about 10 fibers, more preferably at least about 25 fibers, most preferably at least about 50 fibers, especially at least about 100 fibers.  42. The method according to claim 1 or 6, characterized in that the laying of the fibers is carried out at a given angle inside the hydraulically settable mixture to obtain products with the desired fiber concentration.  43. The method according to claim 1 or 6, characterized in that the laying of the fibers is carried out with several different predetermined angles in a hydraulically settable mixture to obtain a product with the required strength properties.  44. The method according to claim 1 or 6, characterized in that the fiber is laid to a predetermined depth inside a hydraulically settable mixture.  45. The method according to claim 1 or 6, characterized in that the hydraulically settable mixture has a viscosity sufficient to reliably tighten the fiber as the hydraulically settable mixture is extruded through a die.  46. The method according to claim 1 or 6, characterized in that at least one fiber has a predetermined tension to improve the laying of the fiber.  47. The method according to item 46, wherein the predetermined tension of the fiber is performed to ensure the winding of the fiber at a given depth inside the hydraulically settable mixture during extrusion of the mixture.  48. The method according to claim 1 or 6, characterized in that during the curing of the hydraulically settable mixture, the extruded hydraulically settable mixture is treated in an autoclave.  49. The method according to claim 1 or 6, characterized in that when the hydraulically settable matrix is cured, an extruded hydraulically settable mixture is placed near the heat source.  50. The method according to claim 1 or 6, characterized in that the tensile strength of the hardened hydraulically settable matrix of an industrial product exceeds about 15 MPa, preferably more than about 30 MPa, especially more than about 50 MPa.  51. The method according to claim 1 or 6, characterized in that the cross-section of the product is performed by at least one of the following: round, rectangular, square, ellipsoid and triangular.  52. The method according to claim 1 or 6, characterized in that the product is a window frame, a tubular object, a sheet or tube. 53. A method of manufacturing an industrial product from a water-curable material, comprising mixing together a hydraulically settable binder, a filler material, a rheological agent, and water in relative concentrations to produce a hydraulically settable mixture having fluidity during extrusion under pressure through a die and immediately acquires shape stability after exiting the die, extrusion of a hydraulically settable mixture under pressure through a die having the axial axis and the inner part through which the mixture passes during extrusion to form an extruded product, continuously laying the fibers in the specified mixture when it is extruded through a die, and curing the extruded hydraulically settable mixture to form a hydraulically settable matrix for the industrial product, characterized in that when laying the fibers in a hydraulically settable mixture, continuous and simultaneous winding is carried out by means of laying at least one wave windows for obtaining an article comprising at least one fiber having a winding angle of at least 5 ^° relative to the longitudinal axis, using styling means configured to directly enter and simultaneously wind at least one fiber wound into entry time with different winding angles of at least 5 ^o relative to the longitudinal axis, with different depths and fiber concentrations inside the hydraulically settable mixture.  54. An extruded industrial product containing a hardened hydraulically settable matrix formed from a hydraulically settable mixture comprising a hydraulically settable binder, at least one filler material and water, and immediately acquires shape stability after leaving the die, and at least two fibers, incorporated into a hydraulically settable matrix and made continuous and flexible enough to fit into a hydraulically settable mixture when it is exposed Extrusion under pressure through a die, characterized in that at least two continuous flexible fibers are laid into a hydraulically settable mixture in cross orientation relative to the longitudinal axis of the article. 55. The product according to item 54, wherein at least one fiber has a winding angle greater than about 20 ^o relative to the longitudinal axis of the die, preferably greater than about 35 ^o relative to the longitudinal axis of the die, more preferably greater than about 50 ^o relative to the longitudinal axis dies, especially greater than about 75 ^o relative to the longitudinal axis of the die.  56. The product according to item 54, wherein the cross-oriented fibers are made of different materials.  57. The product according to item 54, characterized in that it contains at least one other fiber with a substantially parallel orientation relative to the longitudinal axis of the die obtained by the laying operation.  58. The product according to item 54, wherein the fiber is selected from at least one of the following: glass fiber, polyaramide fibers, graphite fibers, carbon fibers, polyethylene fibers, as well as mixtures and derivatives thereof.  59. The product according to item 54, wherein the hydraulically settable binder contains Portland cement, preferably containing at least one of the following: particularly fine-grained cement, slag cement, calcium aluminate cement, plaster, silicate cement, gypsum cement, phosphate cement, white cement, high alumina cement, cement based on magnesium oxychloride, aggregates coated with particles of particularly fine-grained cement, as well as mixtures and derivatives of these materials.  60. The product according to item 54, wherein the hydraulically settable binder contains fly ash activated by a strong alkali.  61. The product according to item 54, wherein the hydraulically settable mixture has an initial water deficit of preferably more than about 10%, more preferably more than about 25%, especially more than about 50%.  62. The product according to item 54, wherein the hydraulically settable mixture, in addition, contains, in principle, uniformly distributed fibers, representing at least one of organic fibers or inorganic fibers.  63. The product according to item 62, wherein the fiber concentration is in the range of from about 0.5 to 30% by volume of the hydraulically settable mixture, preferably in the range of from about 1 to 20% of the volume of hydraulically settable mixture.  64. The product according to item 54, wherein the hydraulically settable mixture contains a dispersant.  65. The product according to item 54, wherein the hydraulically settable mixture further comprises rheological properties, preferably in the range of about 0.1 to 5% by weight of the hydraulically settable mixture except for water, more preferably in the range of about from 0.5 to 1% by weight of a hydraulically settable mixture with the exception of water.  66. The product according to p. 56, characterized in that changing the rheological characteristics of the substance preferably contains one of the following: cellulose-based material, starch-based material, protein-based material, polysaccharide-based material, synthetic organic material or their derivatives.  67. The product according to item 54, wherein the cross-section of the product is at least one of the following: a circle, a rectangle, a square, an ellipse and a triangle.  68. The product according to item 54, wherein the product is a tube, window frame, sheet or tubular object.  69. The product according to item 54, wherein the operation of mixing the components is performed at least partially by means of a mixer with a large shear.  70. The product according to item 54, wherein the hydraulically settable binder and the filler material contain individual particles with a natural packing density in the range from about 0.65 to 0.99, preferably in the range from about 0.75 to 0, nine.  71. The product according to item 54, wherein the filler material is at least one of the following: clay, sand, gravel, alumina, silica sand, fused silica, silica fume, fly ash, crushed limestone, crushed sandstone , crushed granite, crushed basalt, crushed bauxite and mixtures of these materials.  72. The product according to item 54, wherein the filler material has a concentration in the range of from about 3 to 90% by weight of the hydraulically settable mixture, preferably in the range of from about 20 to 70% by weight of the hydraulically settable mixture. 73. The product according to item 54, wherein the product has a bulk density of less than about 1.5 g / cm ³ , preferably less than about 0.3 g / cm ³ . 74. The product according to p. 54, characterized in that the tensile strength under pressure of the hardened hydraulically settable matrix exceeds about 30 N / mm ² , especially exceeds about 50 N / mm ² .  75. The product according to item 54, wherein the fiber concentration is in the range from about 0.55 to 30% by volume of the extruded hydraulically settable mixture, preferably in the range from about 1 to 20% by volume of the extruded hydraulically settable mixture, especially in a range of from about 2 to 10% of the volume of the extruded hydraulically settable mixture.  76. The product according to item 54, wherein it contains at least about 10 fibers, preferably at least about 25 fibers, more preferably at least about 50 fibers, especially at least about 100 fibers.  77. The product according to item 54, wherein the hardened hydraulically settable matrix has a tensile strength of more than about 15 MPa, preferably more than about 30 MPa, especially more than about 50 MPa. 78. An extruded industrial product containing an extruded hydraulically settable hardened mixture comprising products of mixing a hydraulically settable binder, a filler material, a rheological agent, and water, the product having a longitudinal axis and at least two continuous flexible fibers introduced during the extrusion of a hydraulically settable mixture under pressure through a die, characterized in that at least two continuous flexible fibers n winding at an angle of at least 5 ^o relative to the longitudinal axis and at least two continuous flexible fibers are located crosswise. 79. An extrudable industrial product containing an extruded hydraulically settable solidified mixture comprising products of mixing a hydraulically settable binder, a filler material, a rheological agent, and water, the product containing at least two flexible fibers, stacked during extrusion of the mixture under pressure through a die, characterized in that the product has a hollow core, and at least two flexible fibers have a cross orientation and form an angle of at least 10 ^o . Priority on points:
10/04/94 according to claims 1 to 70.

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