Structural element reinforcement systems and methods

1. A reinforced structural element ( 400 ), comprising:

a. a structural element ( 402 ) extending along an axis ( 404 );

b. a sleeve structure ( 410 ) disposed around a length ( 412 ) of the structural element ( 402 ) such that there is a chamber ( 406 ) between the structural element ( 402 ) and the sleeve structure ( 410 ), wherein the sleeve structure ( 410 ) comprises:

i. a first segmented layer ( 412 ), comprising a plurality of first stacked segments ( 416 ) each surrounding the structural element ( 402 ) and a plurality of first horizontal seams ( 418 ) between the first segments ( 416 ), the first segments ( 416 ) disposed along the axis ( 404 ), wherein each first segment ( 416 ) comprises two or more first rigid reinforcing half shells ( 420 ) and two or more first vertical seams ( 424 ) between the first rigid reinforcing half shells ( 420 ); and

ii. a second segmented layer ( 414 ), comprising a plurality of second stacked segments ( 416 ) each surrounding the first segmented layer ( 412 ) and a plurality of second horizontal seams ( 418 ) between the second segments ( 416 ), the second segments ( 416 ) disposed along the axis ( 404 ), wherein each second segment ( 416 ) comprises two or more second rigid reinforcing half shells ( 420 ) and two or more second vertical seams ( 424 ) between the second rigid reinforcing half shells ( 420 ); and

c. a core filler material ( 426 ) disposed within the chamber ( 406 ) between the sleeve structure ( 410 ) and the structural element ( 402 ) so as to reinforce the structural element ( 402 ).

2. The reinforced structural element ( 400 ) of claim 1 , wherein the reinforcing shells ( 420 ) comprise fiber-reinforced shells.

3. The reinforced structural element ( 400 ) of claim 1 , wherein the sleeve structure ( 410 ) additionally comprises one or more wrapped layers ( 430 ), each wrapped layer ( 430 ) formed by wrapping a flexible reinforcing material around one of the segmented layers or another of the wrapped layers ( 430 ).

4. The reinforced structural element ( 400 ) of claim 3 , wherein the flexible reinforcing material is wrapped in a helical or a circumferential pattern.

5. The reinforced structural element ( 400 ) of claim 1 , additionally comprising axial reinforcing members ( 440 ) disposed within the chamber ( 406 ) and encapsulated within the core filler material ( 426 ).

6. The reinforced structural element ( 400 ) of claim 5 , wherein the axial reinforcing members ( 440 ) comprise rigid, semi-rigid, or flexible rods, rigid, semi-rigid, or flexible bars, chains, rebar, or cables.

7. The reinforced structural element ( 400 ) of claim 1 , additionally comprising a plurality of sheer keys ( 450 ), extending radially from a surface ( 408 ) of the structural element ( 400 ) and encapsulated by the core filler material ( 426 ).

8. The reinforced structural element ( 400 ) of claim 1 , wherein the reinforcing shells ( 420 ) of the first segmented layer ( 412 ) comprise shear key protrusions ( 452 ) extending from an interior surface ( 422 ) of the reinforcing shells ( 420 ), the shear key protrusions ( 452 ) encapsulated by the core filler material ( 426 ).

9. The reinforced structural element ( 400 ) of claim 1 , wherein the shear key protrusions ( 452 ) pass through multiple layers of the sleeve structure ( 410 ).

10. The reinforced structural element ( 400 ) of claim 1 , wherein each segment ( 416 ) comprises n reinforcing shells ( 420 ) and n vertical seams ( 424 ), wherein n is an integer between 2 and 10.

11. The reinforced structural element ( 400 ) of claim 1 , wherein the vertical seams ( 424 ) of adjacent segments ( 416 ) are staggered.

12. The reinforced structural element ( 400 ) of claim 1 , wherein the horizontal seams ( 418 ) of the first ( 412 ) and second ( 414 ) segmented layers are staggered.

13. The reinforced structural element ( 400 ) of claim 1 , wherein the sleeve structure ( 410 ) comprises additional layers, each layer comprising a plurality of stacked segments ( 416 ) and a plurality of horizontal seams ( 418 ) between the segments ( 416 ), the segments ( 416 ) disposed along the axis ( 404 ), wherein each segment ( 416 ) comprises two or more reinforcing shells ( 420 ) and two or more vertical seams ( 424 ) between the reinforcing shells ( 420 ).

14. The reinforced structural element ( 400 ) of claim 1 , wherein the reinforcing shells ( 420 ) of each segment ( 416 ) are adhesively or mechanically affixed together.

15. The reinforced structural element ( 400 ) of claim 1 , wherein the reinforcing shells ( 420 ) of the first ( 412 ) and second ( 414 ) segmented layers are adhesively or mechanically affixed together.

16. A system for reinforcing a structural element ( 402 ), comprising:

a. a plurality of reinforcing shells ( 420 ) configured to form a sleeve structure ( 410 ) around a length ( 405 ) of the structural element ( 402 ) such that there is a chamber ( 406 ) between the structural element ( 402 ) and the sleeve structure ( 410 ), wherein the sleeve structure ( 410 ) comprises:

i. a first segmented layer ( 412 ), comprising a plurality of stacked segments ( 416 ) and a plurality of horizontal seams ( 418 ) between the segments ( 416 ), the segments ( 416 ) disposed along an axis ( 404 ), wherein each segment ( 416 ) comprises two or more rigid reinforcing half shells ( 420 ) and two or more vertical seams ( 424 ) between the rigid reinforcing half shells ( 420 ); and

b. a core filler material ( 426 ) configured to fill the chamber ( 406 ) between the sleeve structure ( 410 ) and the structural element ( 402 ) so as to reinforce the structural element ( 402 ).

17. The system of claim 16 , wherein the system additionally comprises a shell adhesive ( 428 ) for affixing the reinforcing shells ( 420 ) together so as to form the sleeve structure ( 410 ).

18. The system of claim 16 , wherein the sleeve structure ( 410 ) additionally comprises a second segmented layer ( 414 ), comprising a plurality of stacked segments ( 416 ) each surrounding the first segmented layer ( 412 ) and a plurality of horizontal seams ( 418 ) between the segments ( 416 ), the segments ( 416 ) disposed along the axis ( 404 ), wherein each segment ( 416 ) comprises two or more reinforcing shells ( 420 ) and two or more vertical seams ( 424 ) between the reinforcing shells ( 420 ).

19. The system of claim 18 , additionally comprising a plurality of spacers ( 454 ) configured to set a desired spacing between the sleeve structure ( 410 ) and the structural element ( 402 ) prior to filling the chamber ( 402 ) with the core filler material ( 426 ).

20. A sleeve structure ( 410 ) for reinforcement of a structural element ( 402 ), the sleeve structure ( 410 ) comprising:

a. a plurality of reinforcing shells ( 420 ) configured to form a sleeve structure ( 410 ) around a length ( 405 ) of the structural element ( 402 ) such that there is a chamber ( 406 ) between the structural element ( 402 ) and the sleeve structure ( 410 ), wherein the sleeve structure ( 410 ) comprises:

i. a first segmented layer ( 412 ), comprising a plurality of first stacked segments ( 416 ) and a plurality of first horizontal seams ( 418 ) between the first segments ( 416 ), the first segments ( 416 ) disposed along an axis ( 404 ), wherein each first segment ( 416 ) comprises two or more first rigid reinforcing half shells ( 420 ) and two or more first vertical seams ( 424 ) between the first rigid reinforcing half shells ( 420 ); and

ii. a second segmented layer ( 414 ), comprising a plurality of second stacked segments ( 416 ) each surrounding the first segmented layer ( 412 ) and a plurality of second horizontal seams ( 418 ) between the second segments ( 416 ), the second segments ( 416 ) disposed along the axis ( 404 ), wherein each second segment ( 416 ) comprises two or more second rigid reinforcing half shells ( 420 ) and two or more second vertical seams ( 424 ) between the second rigid reinforcing half shells ( 420 ).