Modular elements for structural reinforcement

Abstract

A structural element made of a composite material includes a plurality of modular cells disposed within the composite material that have tensile elements that create axially directed tension anchoring elements attached to the tensile elements that create compression with anchoring elements of proximate modular cells. The modular cells may be disposed randomly or in a patterned manner within the composite material. A stackable structural cell facilitates more efficient creation of beams or columns and can include rebar for some of the tension elements that are axially arranged. Additionally, modular cells and/or supported capsules may be added to increase tension and/or decrease mass or weight of the beam or column. The structural cell can further include a boundary layer for containing the composite material prior to hardening.

1 . A structural element, comprising:
 a composite material; and   a plurality of modular cells disposed within the composite material, wherein each of the modular cells includes:   tensile elements that create tension axially along an axis of the tensile elements; and   anchoring elements that create compression with anchoring elements of proximate modular cells, wherein each the anchoring elements is attached to at least one tensile element.   
     
     
         2 . The structural element of  claim 1  wherein the plurality of modular cells are disposed in a random manner within the composite material and create tension in associated random directions. 
     
     
         3 . The structural element of  claim 2  wherein the tension created in associated random directions corresponds with an axial direction of each tensile element of modular cells. 
     
     
         4 . The structural element of  claim 1 , the modular cells comprising a plurality of orthogonally arranged tension elements. 
     
     
         5 . The structural element of  claim 1 , the modular cells comprising six tension elements. 
     
     
         6 . The structural element of  claim 1  wherein the anchoring elements are sized to be in the range of 10 percent to 30 percent of a length of the modular cells. 
     
     
         7 . The structural element of  claim 1  wherein the anchoring elements are sized to be in the range of 5 percent to 30 percent of a length of the modular cell tension elements. 
     
     
         8 . The structural element of  claim 1  wherein the anchoring elements are sized to have a diameter that is larger than a diameter of the tension elements. 
     
     
         9 . The structural element of  claim 1  comprising anchoring elements characterized by a first size at a distal end of each tension element and at least one modular cell having an anchoring element characterized by a second size from which at least two tension elements extend. 
     
     
         10 . The structural element of  claim 9  wherein the second size is approximately the same as the first size. 
     
     
         11 . The structural element of  claim 9  wherein the second size is substantially larger than the first size. 
     
     
         12 . The structural element of  claim 1  comprising at least one structural cell wherein the structural element comprises one of a beam or column. 
     
     
         13 . The structural element of  claim 1  comprising a plurality of structural cell that are mechanically engaged with each other and wherein the structural element forms one of a beam or column. 
     
     
         14 . A structural element, comprising:
 a composite material; and   at least one structural cell wherein the at least one structural cell further includes:   axially arranged first tension elements that are substantially parallel to each other;   at least one supporting member coupled to all of the axially arranged tension elements to define a shape of the structural element; and   first and second interlocking elements, wherein:
 the first interlocking elements are disposed at a first end of each of the axially arranged tension elements; 
 the second interlocking elements are disposed at a second end of each of the axially arranged tension elements; and 
 the first and second interlocking elements are shaped and sized to mechanically engage each other so that other similar structural elements may be stacked to form a column or beam. 
   
     
     
         15 . The structural element of  claim 14  further including a boundary layer for holding the composite material until the composite material has hardened. 
     
     
         16 . The structural element of  claim 15  wherein the boundary layer is removable after the composite material has hardened. 
     
     
         17 . The structural element of  claim 14  further including second tension elements disposed perpendicularly to the axially arranged first tension elements. 
     
     
         18 . The structural element of  claim 17  further including at least one capsule that reduces an amount of composite required to form the structural element, wherein each capsule of the at least one capsule is supported by the second tension elements. 
     
     
         19 . The structural element of  claim 14  further including a plurality of modular cells that are arranged either in a pattern or randomly or both. 
     
     
         20 . The structural element of  claim 19  wherein at least a portion of the plurality of modular cells are coupled to at least one of the first tension elements or second tension elements. 
     
     
         21 . A structural element, comprising:
 axially arranged first tension elements;   second tension elements disposed substantially perpendicular to the first tension elements;   a composite material wherein the first and second tension elements are disposed within the composite material; and   modular cells disposed within the composite material to create tension in a plurality of directions, the modular cells each having tension elements and anchoring elements disposed at distal ends of the modular cell tension elements.   
     
     
         22 . The structural element of  claim 21  further including at least one of gravel and rocks within the composite material. 
     
     
         23 . The structural element of  claim 21  wherein the modular cells are disposed in a patterned manner to create tension along desired directions. 
     
     
         24 . The structural element of  claim 21  wherein the modular cells are disposed in a random manner to create tension along a plurality of directions that are not necessarily orthogonal to first and second tension elements.