Structural barrier and a method of installation thereof

A structural barrier and energy absorbing device comprises a plurality of structural elements. The structural element alone or in a plurality may serve as a traversal impediment or energy absorbing device, such as a pedestrian barrier, vehicular barrier, anti-tank obstacle, ballistic barrier, or the like. The structural element may be a tetrapod such that it comprises an element body having four extension portions that extend outwardly from the interior center to a distal end, such that the structural element maintains an identical orientation and a low center of gravity in each of four resting positions. The structural element may be a solid-state structural element comprised of a particular material or a portable and collapsible structural element wherein the element body comprises an outer skin defining an interior void space, such that during set-up or installation the interior void space may be filled with a filler substance onsite.

TECHNICAL FIELD

The present disclosure relates to a structural barrier composed of one or more structural elements and methods of installation of the same.

BACKGROUND

This invention relates to structural elements for barriers for engineering uses such as river and canal engineering, erosion control, embankment and levee construction, and construction for protection of sea coasts, harbors, and lakeshores.

Structural barriers of various configurations have been utilized for such purposes. However, while a large variety of block-like structures have been proposed and made, e.g., jersey barriers, caltrops, X-blocs, etc., these conventional blocks have not been entirely satisfactory. Furthermore, known blocks and barriers, in general, have entailed high production costs, limited options for transport and installation, and the modes of combination between like blocks or barriers have been limited.

SUMMARY

A structural barrier and methods of installation for the same are provided. The structural barrier may comprise a plurality of structural elements or energy absorbing devices arranged such that the structural elements are configured to receive and interlock with one another to form the structural barrier. The structural elements may be solid-state structural elements comprised of a concrete material, a ballistic material, aggregate material coupled by a bonding adhesive or the like. The structural elements may alternatively be a portable and collapsible structural elements, wherein the element body comprises an outer skin defining an interior void space, such that upon set-up or installation the interior void space may be filled with a filler substance onsite after positioning of the outer skin in the selected installation location.

A single structural element may be referred to as a tetrapod, as the structural element more particularly comprises an element body having an exterior surface and an interior center. The element body may be portioned into a first bisection and a second bisection. The element body may further define a plurality of extension portions, namely a first extension portion, a second extension portion, a third extension portion, and a fourth extension portion, each positioned on a unique axis that extend in a predetermined direction along the respective axis outwardly from the interior center to a distal end.

Each of the respective unique axes defines an angle with each of the other unique axes at the interior center, such that the angle between each of the respective axes is substantially equivalent. Accordingly, the first bisection includes three of the four extension portions, such that the respective distal ends thereof are positioned on a geometric plane, and the second bisection includes the one remaining extension portion, such that the respective extension portion and the respective axis in the second bisection extend outwardly from the interior center to the respective distal end orthogonal to the geometric plane. In this way, the structural element has the capability of maintaining an identical orientation and a low center of gravity in each of four different resting positions.

The structural element alone or in a plurality thereof may serve as a traversal impediment, energy absorbing device, or more particularly the structural barrier claimed herein, wherein the structural barrier is one of a pedestrian barrier, vehicular barrier, anti-tank obstacle, ballistic barrier, construction barrier, an eco-barrier for erosion control, or the like. When organized in a plurality, the structural elements may be randomly organized and stacked, such that the respective extension portions of the structural elements interlock with one another to form an extended barrier or obstacle. Further, when each structural element is interlocked with at least one of the other structural elements of the structural barrier, the respective extension portions define a plurality of void spaces therebetween.

The methods of installation for the structural barrier may include the steps of: providing a negative form, in the form of the structural element; applying an outer skin material to the external form surface of the negative form until the outer skin material has a thickness of greater than 0.125 inches; removing the outer skin from the negative form; filling the interior void space defined by the outer skin with a filler substance, wherein the filler substance is at least one of a fluid, an aggregate, a soil, or a combination thereof; selecting an installation location and orientation for the structural element; and positioning the structural element in the installation location.

DETAILED DESCRIPTION

While the present disclosure may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure. Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” etc., are used descriptively of the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the disclosure in any way.

Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description.

The following discussion and accompanying figures disclose various configurations of structural elements and pluralities of structural elements configured to form traversal impediments or energy absorbing devices, such as a pedestrian barrier, vehicular barrier, anti-tank obstacle, ballistic barrier, construction barrier, an ecobarrier for erosion control, or the like. The components of the disclosed embodiments, as described and illustrated herein, may be arranged and designed in a variety of different configurations. Thus, the following detailed description is not intended to limit the scope of the disclosure, as claimed, but is merely representative of possible embodiments thereof. For example, although the structural element is depicted as a tetrapod in the associated Figures, concepts associated with the configurations and methods may be applied to various types of structural elements of varying configurations. Further, non-tetrapod structural elements may also incorporate concepts discussed herein.

In addition, while numerous specific details are set forth in the following description in order to provide a thorough understanding of the embodiments disclosed herein, some embodiments can be practiced without some of these details. Moreover, for the purpose of clarity, certain technical material that is understood in the related art has not been described in detail in order to avoid unnecessarily obscuring the disclosure. Furthermore, the disclosure, as illustrated and described herein, may be practiced in the absence of an element that is not specifically disclosed herein.

In the vehicular management, pedestrian management, crowd control, and roadway construction context, conventional barriers may be large, heavy, and difficult to transport, and few maintain the desired traffic management features while still providing an energy absorption and dissipation function for the safety of the pedestrian, driver, and/or surrounding bystanders in the event a pedestrian or a vehicle contacts the barrier. The structural barrier120formed via a plurality of structural elements10of the present disclosure cures these deficiencies and has industrial applicability as a traffic barrier and/or a crowd control device.

In a water management context, e.g., wave breaking, river and canal engineering, erosion control, construction for protection of sea coasts, harbors, and lakeshores, etc. conventional structural elements and applications such as concrete blocks and boulders tend to come dislodged over time by force of water and wave action, whereby they cannot function effectively as wave dissipation means or to control erosion. As such, the structural barrier120formed via a plurality of structural elements10described herein has industrial applicability as a barrier for engineering uses such as river and canal engineering, erosion control, embankment and levee construction, construction for protection of sea coasts, harbors, and lakeshores.

Referring to the drawings, the elements shown inFIGS. 1-23, are not necessarily to scale or proportion. Accordingly, the particular dimensions and applications provided in the drawings presented herein are not to be considered limiting. Further, referring to the drawings, a structural element10is provided. In a general sense, the structural element10of the present disclosure includes a structural element10and energy absorbing device, which may be a solid-state structural element10comprised of a predetermined moldable, formable, and/or curable materials, for example, a concrete material, a ballistic material, or the like. The structural element10may also be a solid-state structural element10comprised of an aggregate material comprising a plurality of aggregate pieces bonded together with an adhesive.

The structural element10may alternatively be a portable and collapsible structural element10wherein the element body12comprises an outer skin14defining an interior void space16, such that the outer skin14may be easily transported and then upon set-up or installation at a selected installation location, the interior void space16defined by the outer skin14may be filled with a filler substance on-site. The filler substance may include, a fluid such as water, an aggregate such as sand, a soil, or another filler substance depending upon the particular application of the barrier120and/or the structural element10in use, considering, for example, the type, size and function of the object or objects being barricaded, impeded or obstructed, energy absorption requirements, ballistic resistance, permanency of the structure, etc.

As shown by example inFIGS. 1-8B, a single structural element10may be referred to as a tetrapod, as the structural element10comprises an element body12, which is divided into a first bisection32and a second bisection30. The element body12further comprises a plurality of extension portions20,22,24,26each positioned on a unique axis A1, A2, A3, A4and extending in a predetermined direction along the respective axis A1, A2, A3, A4outwardly from the interior center C to a distal end21,23,25,27. Accordingly, the first bisection32includes three of the four extension portions20,22,24,26, such that the respective distal ends21,23,25,27thereof are positioned on and in contact with a geometric plane P, and the second bisection30includes the one remaining extension portion20,22,24,26, such that the respective extension portion and the respective axis in the second bisection30extend outwardly from the interior center C of the element body12to the respective distal end21,23,25,27and orthogonal to the plane P.

Each of the respective axes defines an angle34with each of the other axes at the interior center C, such that the angle34between each of the respective axes is substantially equivalent. In this way, the structural element10maintains an identical orientation and a low center of gravity in each of four different resting positions34,36,38,40.

The structural element10alone or in a plurality thereof120(FIGS. 18-21) may serve as a traversal impediment or energy absorbing device, such as a pedestrian barrier, vehicular barrier, anti-tank obstacle, ballistic barrier, construction barrier, or the like. A plurality of structural elements120may also serve as a jetty, breakwater, or erosion control device portioned proximate to a shoreline.

Referring first toFIGS. 1-8B, the structural element10may include an element body12having an exterior surface13and an interior center C. The element body12may further include a plurality of extension portions20,22,24,26that extend outwardly from the interior center C to a distal end21,23,25,27along a length88. Each extension portion20,22,24,26may be disposed on an individual axis A1, A2, A3, A4, such that the respective extension portion20,22,24,26extends outwardly from the interior center C in a predetermined direction D1, D2, D3, D4to the distal end21,23,25,27.

Collectively, the axes A1, A2, A3, A4define a plurality of axes, such that each axis defines and an angle34with each of the other axes at the interior center C, such that the angle34between each of the respective axes A1, A2, A3, A4is substantially equivalent.

More particularly, the plurality of extension portions20,22,24,26may include, a first extension portion20, a second extension portion22, a third extension portion24, and a fourth extension portion26. The first extension portion20may be disposed on a first axis A1, such that the first extension portion20extends outwardly from the interior center C in a first predetermined direction D1to a first distal end21along a first length88a.The second extension portion22may be disposed on a second axis A2, such that the second extension portion22extends outwardly from the interior center C in a second predetermined direction D2to a second distal end23along a second length88b.The third extension portion24may be disposed on a third axis A3, such that the third extension portion24extends outwardly from the interior center C in a third predetermined direction D3to a third distal end25along a third length88c.The fourth extension portion26may be disposed on a fourth axis A4, such that the fourth extension portion26extends outwardly from the interior center C in a fourth predetermined direction D4to a fourth distal end27along a fourth length88d.Each of the first predetermined direction D1, the second predetermined direction D2, the third predetermined direction D3, and the fourth predetermined direction D4are different from each of the other predetermined directions D1, D2, D3, D4.

In accordance with the above description andFIG. 1-8B, a single structural element10may be referred to as a tetrapod. More particularly, the structural element10comprises an element body12, which is divided into the first bisection32and the second bisection30, wherein the first bisection32includes three of the four extension portions20,22,24,26or legs, such that the respective distal ends21,23,25,27thereof are positioned on a geometric plane P, and the second bisection30includes one remaining extension portion20,22,24,26or leg, such that the respective extension portion in the second bi-section30and the respective axis A1, A2, A3, A4in the second bisection30extend outwardly from the interior center C of the element body12to the respective distal end21,23,25,27orthogonal to the geometric plane P.

As shown by example inFIGS. 3 and 8A-8B, the first bisection32may have a first height15and the second bisection30may have a second height19. Collectively, the first bisection32and the second bisection30may define an overall height17. The structural element10may occupy one of four resting positions, namely, a first resting position34, a second resting position36, a third resting position38, and a fourth resting position40. In this way, when the respective lengths88a,88b,88c,and88dare substantially equivalent, the structural element10maintains an identical orientation and a low center of gravity in each of four different resting positions34,36,38,40as illustrated inFIGS. 1-8B.

As shown by example inFIGS. 1 and 5, in the first resting position34, the first bisection32includes each of the second extension portion24, the third extension portion26, and the fourth extension portion28. In this way, the second distal end23, the third distal end25, and the fourth distal end27are positioned in contact with geometric plane P. The second bisection30includes the first extension portion20, such that the first extension portion20and the first axis A1extend outwardly from the interior center C to the first distal end21along the first length88aorthogonal to the geometric plane P.

As shown by example inFIGS. 2 and 6, in the second resting position36, the first bisection32includes each of the first extension portion20, the third extension portion24, and the fourth extension portion26. In this way, first distal end21, the third distal end23, and the fourth distal end27are positioned in contact with the geometric plane P. The second bisection30includes the second extension portion22, such that the second extension portion22and the second axis A2extend outwardly from the interior center C to the second distal end23along the second length88borthogonal to geometric plane P.

As shown by example inFIG. 3, in the third resting position38, the first bisection32includes each of the first extension portion20, the second extension portion22, and the fourth extension portion26. In this way, the first distal end21, the second distal end23, and the fourth distal end27are positioned in contact with the geometric plane P. The second bisection30includes the third extension portion24, such that the third extension portion24and the third axis A3extend outwardly from the interior center C to the third distal end25along the third length88corthogonal to the geometric plane P.

As shown by example, inFIGS. 4 and 8A, in the fourth resting position40, the first bisection32includes each of the first extension portion20, the second extension portion22, and the third extension portion24. In this way, the first distal end21, the second distal end23, and the third distal end25are positioned in contact with the geometric plane P. The second bisection30includes the fourth extension portion26, such that the fourth extension portion26and the fourth axis A4extend outwardly from the interior center C to the fourth distal end27along the fourth length88dorthogonal to the geometric plane P.

In some examples, the respective extension portion20,22,24,26, embodied in the second bisection30may be of a substantially different length88a,88b,88c,88dthan each of the other extension portions20,22,24,26, which are positioned in the first bisection30. In some embodiments the extension portion20,22,24,26within the second bisection30may have a length88a,88b,88c,88dthat is substantially greater or longer than the length88a,88b,88c,88dof each of the other extension portions in the first bisection32, which would provide for an increase in the overall height17of the structural element10. In other embodiments the extension portion20,22,24,26within the second bisection30may have a length88a,88b,88c,88dthat is substantially shorter than the length88a,88b,88c,88dof each of the other extension portions in the first bisection32, which may provide for a decrease in the overall height17of the structural element10.

In examples wherein the respective extension portion20,22,24,26, embodied in the second bisection30may be of a substantially different length88a,88b,88c,88dthan each of the other extension portions20,22,24,26contained within the first bisection32, in the first resting position34(FIGS. 1 and 5), the second bisection30includes the first extension20portion, such that the first extension portion20may define a length88athat is substantially longer or shorter than the lengths88b,88c,88dof each of the second extension portion22, the third extension portion24, and the fourth extension portion26. In the second resting position36(FIGS. 2 and 6), the second bisection30includes the second extension portion22, such that the second extension portion22may define a length88bthat is substantially longer or shorter than the lengths88a,88c,88dof each of the first extension portion20, the third extension portion24, and the fourth extension portion26. In the third resting position38(FIG. 3), the second bisection30includes the third extension portion24, such that the third extension portion24may define a length88cthat is substantially longer or shorter than the lengths88a,88b,88dof each of the first extension portion20, the second extension portion22, and the fourth extension portion26. In the fourth resting position40(FIGS. 4 and 8A), the second bisection30includes the fourth extension portion26, such that the fourth extension portion26may define a length88dthat is substantially longer or shorter than the lengths88a,88b,88cof each of the first extension portion20, the second extension portion22, and the third extension portion24.

As shown by example inFIGS. 1-4, each of the extension portions20,22,24,26may be substantially conical, in that each of the first extension portion20, the second extension portion22, the third extension portion24, and the fourth extension portion26is formed as a truncated cone. As shown by example, inFIGS. 1 and 2, each of the first distal end21, the second distal end23, the third distal end25, and the fourth distal end27maintain a flattened and substantially circular cross-sectional configuration.

As shown by example inFIGS. 3 and 4, each of the extension portions20,22,24,26may be substantially conical, in that each of the first extension portion20, the second extension portion22, the third extension portion24, and the fourth extension portion26is formed as a plurality of truncated cones. As shown inFIGS. 3 and 4, the distal ends21,23,25,27each define a flattened and substantially-circular cross-sectional configuration.

The plurality of truncated cones may include a first truncated cone42and a second truncated cone44. The first truncated cone42extends from the interior center C to an extension portion intermediate point45. The respective extension portion20,22,24,26has a first cross-sectional diameter46at the extension portion intermediate point45. The second truncated cone44extends from the extension portion intermediate point45to the distal end21,23,25,27. The respective extension portion20,22,24,26has a second cross-sectional diameter48at the distal end21,23,25,27. The second cross-sectional diameter48is smaller than the first cross-sectional diameter46of each of the extension portions20,22,24,26.

The first cross-sectional diameter46and the second cross-sectional diameter48may be smaller than the interior base cross-sectional diameter51(FIG. 8B) of the respective extension portion20,22,24,26, thereby defining a taper from the interior center C to the respective distal end21,23,25,27. The degree of the taper may be defined by angle53(FIG. 8B) defined between the tapered exterior surface of the respective extension portion20,22,24,26and a line parallel to the respective axis A1, A2, A3, A4running through the highest point47on top of the respective extension portion20,22,24,26at the intermediate point45.

Alternatively, as shown inFIGS. 5-8B, each of the first extension portion20, the second extension portion22, the third extension portion24, and the fourth extension portion26may be formed as a polygonal prism. As shown by example, inFIGS. 5-8B, each of the first distal end21, the second distal end23, the third distal end25, and the fourth distal end27maintain a flattened, polygonal cross-sectional configuration. As shown inFIGS. 5-8B, the distal ends21,23,25,27each define a flattened, polygonal, e.g., pentagonal, hexagonal, octagonal etc. cross-sectional configuration.

The polygonal prism may be a pentagonal prism, such that each of the first distal end21, the second distal end23, the third distal end25, and the fourth distal end27maintain flattened pentagonal cross-sectional configuration. The polygonal prism may be a hexagonal prism, such that each of the first distal end21, the second distal end23, the third distal end25, and the fourth distal end27maintain flattened hexagonal cross-sectional configuration. The polygonal prism may be an octagonal prism, such that each of the first distal end21, the second distal end23, the third distal end25, and the fourth distal end27maintain flattened octagonal cross-sectional configuration.

In one example, as shown inFIGS. 5-8B, each of the first extension portion20, the second extension portion22, the third extension portion24, and the fourth extension portion26is formed as a plurality of polygonal prisms. The plurality of polygonal prisms may include a first polygonal prism50and a second polygonal prism52. The first polygonal prism50extends from the interior center C to an extension portion intermediate point45. The respective extension portion20,22,24,26has a first cross-sectional diameter46at the extension portion intermediate point45. The second polygonal prism52extends from the extension portion intermediate point45to the distal end21,23,25,27. The respective extension portion20,22,24,26has a second cross-sectional diameter48at the distal end21,23,25,27. The second cross-sectional diameter48is smaller than the first cross-sectional diameter46of each of the extension portions20,22,24,26.

The first cross-sectional diameter46and the second cross-sectional diameter48may further be smaller than the interior base cross-sectional diameter51of the respective extension portion20,22,24,26, thereby defining a taper from the interior center C to the respective distal end21,23,25,27. The degree of the taper may be defined by angle53(FIG. 8B) defined between the tapered exterior surface of the respective extension portion20,22,24,26and a line parallel to the respective axis A1, A2, A3, A4running through the highest point47on top of the respective extension portion20,22,24,26at the intermediate point45.

Structural elements10having extension portions20,22,24,26formed as polygonal prisms50,52, may have advantages over structural elements12having extension portions20,22,24,26formed as truncated cones42,44in that structural elements12having extension portions20,22,24,26formed as a polygonal prisms may be more stable and more difficult to topple or move from one resting position34,36,38,40to another resting position34,36,38,40. Further, structural elements10having an extension portion20,22,24,26in the second bisection30having a substantially shorter length88a,88b,88c,88dthat the extension portions20,22,24,26of the first bisection32, may be substantially more stable and more difficult to topple or move from one resting position34,36,38,40to another resting position34,36,38,40. Structural elements10having extension portions20,22,24,26formed as a polygonal prisms may be particularly advantageous in defense applications due to the unique geometry thereof being particularly apt to high-center a vehicle upon contact, such as when used as part of a traffic barrier that comprises and anti-tank obstacle as described herein below.

The structural element10of the present disclosure may be a solid-state structural element10comprised of a predetermined moldable, formable, and/or curable material, for example, a concrete material, a ballistic material, or the like. The structural element10may also be a solid-state structural element10comprised of an aggregate material comprising a plurality of aggregate pieces bonded together with an adhesive. Alternatively, the structural element10may be a portable and collapsible structural element10wherein the element body12comprises an outer skin14defining an interior void space16, such that the outer skin14may be easily transported and then upon set-up or installation the interior void space16may be filled with a filler substance on site in the selected installation location.

In a first example wherein, the structural element10is a solid-state structural element10, the structural element10may be comprised of a predetermined moldable, formable, and/or curable material, for example, a concrete material, a ballistic material, or the like. The structural element10may further comprise a reinforcing structure54as shown by example inFIG. 9A and 9B. The reinforcing structure54may be comprised of a metallic material, for example steel rebar. The steel rebar may have a cross-sectional diameter of 0.5 inches or greater.

As shown by example inFIG. 9A, the steel rebar reinforcing structure54may comprise a plurality of flange elements, namely a first plurality of flange elements72, a second plurality of flange elements74, a third plurality of flange elements76, and a fourth plurality of flange elements78that each extend outwardly from the interior of the element body12and through one of the extension portions20,22,24,26.

Each extension portion20,22,24,26may contain at least one flange element72,74,76,78of the reinforcing structure54extending therethrough. In this way, the first plurality of flange elements72is disposed on the first axis A1and extends outwardly from the interior center C toward the first distal end21along the length88a.The second plurality of flange elements74is disposed on the second axis A2and extends outwardly from the interior center C toward the second distal end23along the length88b.The third plurality of flange elements76is disposed on the third axis A3and extends outwardly from the interior center C toward the third distal end25, along the length88c.The fourth plurality of flange elements78is disposed on the fourth axis A4and extends outwardly from the interior center C toward the fourth distal end27along the length88d.

The reinforcement structure54may further comprise a plurality of circumferential elements80,82,84,86(FIG. 9B) coupled to the plurality of flange elements72,74,76,78. A first plurality of circumferential elements80is coupled to the first plurality of flange elements72along the length88aof the first extension portion20. The first plurality of circumferential elements80may be positioned evenly and equidistantly along the length88aof the first extension portion20between the interior center C and the first distal end21. A second plurality of circumferential elements82is coupled to the second plurality of flange elements74along a length88bof the second extension portion22. The second plurality of circumferential elements82may be positioned evenly and equidistantly along the length88bof the second extension portion22between the interior center C and the second distal end23. A third plurality of circumferential elements84is coupled to the third plurality of flange elements76along a length88cof the third extension portion24. The third plurality of circumferential elements84may be positioned evenly and equidistantly along the length88cof the third extension portion24between the interior center C and the third distal end25. A fourth plurality of circumferential elements86is coupled to the fourth plurality of flange elements78along a length88dof the fourth extension portion26. The fourth plurality of circumferential elements78may be positioned evenly and equidistantly along the length88dof the fourth extension portion26between the interior center C and the fourth distal end27.

The solid-state, structural element10may be formed via a formation mold56, as shown inFIGS. 10-14. The formation mold56may be a metallic mold56formed of steel, aluminum, or the like. The mold56may be formed from a mold set containing five mold portions58,60,62,64,68, namely three upper mold portions58,60,62one lower mold portion64, and a mold base68. The three upper mold portions58,60,62and the lower mold portion64define an interior mold space11therebetween. The three upper mold portions58,60,62and the lower mold portion64define an inwardly facing mold surface94flush with the interior mold space11and an external mold surface96.

The reinforcement structure54may be placed upon the lower mold portion64in contact with the inwardly facing mold surface94within the interior mold space11. Each of the three upper mold portions58,60,62are bolted and pinned together via flange elements98to form the mold upper, such that the mold upper is placed about the reinforcement structure54and bolted and pinned to the lower mold portion64via substantially similar flange elements98. The assembled mold form56is disposed upon mold base68.

The solid-state structural element10is then formed via injecting the predetermined moldable, formable, and/or curable material into the interior mold space11such that the material envelopes the reinforcing structure54and expands to contact each of the mold portions58,60,62,64. The predetermined moldable, formable, and/or curable material may be a concrete material, an aggregate material, a polymeric material, Nylon, a foam material such as a structural foam, or another solid-state material. In an example, wherein the material is a concrete material, the concrete material may have a design strength of about 4800 PSI and an approximate cure time of five (5) days. The material may also comprise a ballistic material, such as a ballistic slag material, a ballistic concrete, a ballistic Nylon, Kevlar, or the like configured to be stab-resistant and ballistic projectile resistant. In a non-limiting example, the structural element10may be comprised of a concrete-based composite material as disclosed by U.S. Provisional Application No. 62/898771, filed Sep. 11, 2019, which is hereby incorporated by reference in its entirety.

In a second example wherein, the structural element10is a solid-state structural element10, the structural element10may be comprised of an aggregate material having a plurality of aggregate pieces bonded together via an adhesive. More particularly, the plurality of aggregate pieces may be a plurality of recycled concrete pieces, a plurality of recycled slag material pieces, or a plurality of recycled ballistic material pieces, or the like. The adhesive may be a two-part glue and resin mixture or the like. The structural element10may further comprise a reinforcing structure54as shown by example inFIG. 9A and 9B.

This second example solid-state, structural element10may be formed via the method200disclosed herein and detailed via the flow diagram inFIG. 23. The second example solid-state structural element10may be formed using a negative form56(FIGS. 10, 12, 15). As such, at step201a negative form56is provided, wherein the negative form56comprises a form body58,60,62,64, the form body58,60,62,64having an external form surface96and an interior center. The negative form56may be formed of a fiberglass material or another suitable material. The negative mold56may further define the external mold surface96.

Further, the negative form56mirrors the form of the structural element10, in that the negative form56further defines a first extension portion20disposed on a first axis A1and extending outwardly from the interior center in a first predetermined direction D1to a first distal end21, the first extension portion20defining a plurality of first extension portion flange members98that extend outwardly therefrom. A second extension portion22is disposed on a second axis A2extending outwardly from the interior center in a second predetermined direction D2to a second distal end23, the second extension portion22defining a plurality of second extension portion flange members98that extend outwardly therefrom. A third extension portion24is disposed on a third axis A3extending outwardly from the interior center in a third predetermined direction D3to a third distal end25, the third extension portion24defining a plurality of third extension portion flange members98that extend outwardly therefrom. A fourth extension portion26is disposed on a fourth axis A4extending outwardly from the interior center in a fourth predetermined direction D4to a fourth distal end27, the fourth extension portion26defining a plurality of fourth extension portion flange members98that extend outwardly therefrom. Each of the first axis A1, the second axis A2, the third axis A3, and the fourth axis A4defines an angle with each of the other axes at the interior center, and wherein the angle between each of the respective axes is substantially equivalent. In this way, the exterior mold surface96defines the interior void space16of the outer skin14.

At step202, optionally, the negative mold56may be covered with a mesh70. In one example, the mesh70is a metallic or wire mesh, such as a metallic mesh70, as shown by example inFIG. 15, such that the metallic or wire mesh70is in contact with external mold surface96. Other mesh materials may be used, including, for example, the mesh70can be a polymeric-based mesh, such as a molded or woven plastic mesh, a textile-based mesh such as a woven or knotted fabric or rope mesh, or the like The mesh70may have varying cell size and configuration. The mesh is designed to allow the outer skin material to be applied to the external mold surface96to form the outer skin14without adhering to the negative mold56.

At step203, a silicone material is applied to the external mold surface96of the negative form56until the silicone material has a thickness95of greater than 0.125 inches, such that the silicone material forms an outer skin14in the form of the structural element10defining an interior void space16. In one example, the silicone material is sprayed onto the external mold surface96of the negative mold56.

At step204a curing or drying process is initiated for the silicone material, and upon completion of the curing or drying process, the silicone material may be removed from the negative mold56, such that the outer skin14defines an interior void space16. At step205, the interior void space16defined by the outer skin14may be filled with a filler substance, wherein the filler substance is an aggregate comprising a plurality of aggregate pieces. The plurality of aggregate pieces may be a plurality of recycled concrete pieces, a plurality of recycled slag material pieces, or a plurality of recycled ballistic material pieces, or the like. The adhesive may be a marine glue or the like. The plurality of aggregate pieces may fill from about 75% to about 85% of the interior void space16, such that the interior of the outer skin14comprises from about 15% to about 25% voids between the respective aggregate pieces. The filler substance may also include a metallic component and/or metallic-based particles, such as metal-based shot, metal-based pellets, such as iron-based pellets or taconite pellets, iron-based particles, or the like that may be inserted into the interior void space16to fill the respective voids between the aggregate pieces, and thereby add mass and/or weight to and/or increase the density of the solid-state structural element10.

At step206, an adhesive is injected into the interior void space16to bind the aggregate pieces and any metallic based particles to the other respective aggregate pieces within the outer skin14. The adhesive may be a two-part glue and resin mixture, such as a marine glue or the like. One such suitable adhesive is a two-part glue and resin mixture that is commercially-available from BASF Group under the trade name Elastotite® Rock Glue 2K Resin. At step207, a curing or drying process for the adhesive is initiated.

Upon completion of the curing or drying process for the adhesive, and at step208, the outer skin14formed of the silicone material may be removed from the bonded combination of aggregate pieces of the filler substance and the adhesive.

At step209, an installation location may be selected. At step210, a first structural element10may be positioned in the selected installation location; and at step211, a plurality of subsequent structural elements10may be positioned in the selected installation location, such that the first structural element and the subsequent structural elements comprise the structural barrier120.

The process of filing a silicone outer skin14with an aggregate and binding adhesive as detailed in method200is advantageous in that it produces solid-state structural elements10of substantially lighter weight than the solid-state structural elements10formed of the moldable, curable material such as concrete allowing for a larger variety of installation locations. Further, the mass or weight of the solid-state structural elements10formed in accordance with method200allow for a customizable mass or weight of the element10, which may be adjusted or manipulated via the addition of the metallic-based particles detailed herein.

These advantages translate particularly well in the traffic management context in that these structural elements10are more easily transported and positioned in heavily trafficked and densely populated cities for traffic management, as pedestrian barriers, traffic barriers, crowd control device, or construction barriers. These advantages also translate particularly well in the water management or erosion control context, as solid-state structural elements10of concrete or the like are heavy enough that in marine applications, the same require difficult transport by barge, whereas solid-state structural elements10formed via the process200of filling a silicone skin14with an aggregate and binding adhesive may be formed as one of a jetty, a breakwater, or an erosion control apparatus positioned in shallow areas of a body of water, e.g., less than three to four feet of depth, that cannot be reached by barge. These solid-state structural elements10may also utilize adhesives having a relative short cure times, e.g., less than one hour. Accordingly, such elements10may be formed in the field, such as on barge or during vehicular transport and then positioned or installed in the desired installation location.

In water management and erosion control applications, the plurality of structural elements120may be positioned in the form of an elongated mound. The elongated mound may comprise a front sloping side wall facing seaward, a rear sloping side wall facing landward, and the plurality of structural elements120covering the seaward slope. Each structural element10of the plurality120is interlocked with at least one other structural element10, the respective extension portions20,22,24,26define void spaces therebetween. The void spaces cooperate to provide a substantial volume of void spaces between the plurality of structural elements120, such that the void spaces are large enough to allow water to pass through the elongated mound, so that the plurality of structural elements120maintains a high degree of permeability to water and maintains stability under wave action and hydraulic roughness. As such, the volume of void spaces between the plurality of structural elements120is still small enough to allow trap sediment to collect under and within the plurality of structural elements120to mitigate erosion.

In the portable and collapsible structural element10example, the structural element10comprises an element body12defined by an outer skin14. The outer skin14defines an interior void space16. In this example, the outer skin14may be collapsible such that it is easily transported and then upon set-up or installed at a selected installation location, where the interior void space16may be filled with a filler substance on site.

In such an example, the element body12comprises the outer skin14, which is comprised of a polyurea-based material or a similar material. The polyurea-based material may include a primer, a performance-based basecoat, and a polyurea-based topcoat. One commercially available example primer is the VersaFlex VF 20 primer; one commercially-available performance basecoat is the VersaFlex FSS 45DC, which is a one hundred percent solids, plural-component, aromatic-based polyurea elastomer system, which passes ASTM C 1305; and one commercially-available performance topcoat is an aliphatic polyurea system such as the VersaFlex GelFlex 1115 system, which is a plural-component, one hundred percent solids, aliphatic polyurea.

The outer skin14may define an inwardly facing surface91and an outwardly facing surface93, and a thickness95defined from the inwardly facing surface91to the outwardly facing surface93. The thickness is greater than about 0.125 inches.

The outer skin14may further comprise a plurality of outer skin portions14A,14B,14C,14D (FIGS. 16-17), wherein each of the outer skin portions14A,14B,14C,14D are substantially identical. Each of the outer skin portions14A,14B,14C,14D may have a thickness95of 0.125 inches or greater. Each of the outer skin portions14A,14B,14C,14D (FIG. 16) defines an outer periphery41and a plurality of connection edges99formed along the outer periphery41of the respective outer skin portion14A,14B,14C,14D. Connection edges99of each of the outer skin portions14A,14B,14C,14D are configured to be coupled to the connection edges99of at least one other outer skin portion14A,14B,14C,14D (FIG. 17), such that when the outer skin portions14A,14B,14C,14D are fixedly coupled to one another, the outer skin portions14A,14B,14C,14D collectively define each of the first extension portion20, the second extension portion22, the third extension portion24, the fourth extension portion26of the portable and collapsible structural element10and an interior void space16therebetween.

The portable and collapsible structural element10may further include a reinforcing structure54(FIG. 9B). The reinforcing structure54may comprise a plurality of circumferential elements80,82,84,86positioned in contact with the inwardly facing surface91of the outer skin14and about each of the extension portions20,22,24,26. As shown by example inFIG. 9B, the reinforcing structure54may further comprise a plurality of circumferential elements80,82,84,86positioned about each of the extension portions20,22,24,26. Each circumferential element80,82,84,86may be composed of a textile material, such as Nylon rope. Each circumferential element80,82,84,86may also comprise a metallic, polymeric, or fiberglass element wrapped about or covered with a textile material.

More particularly, a first plurality of circumferential elements80may be disposed about the first extension portion20along the length88aof the first extension portion20. The first plurality of circumferential elements80may be distributed along the length88a,for example, positioned evenly and equidistantly along the length88a,of the first extension portion20between the interior center C and the first distal end21. A second plurality of circumferential elements82may be disposed about the second extension portion22along the length88bof the second extension portion22. The second plurality of circumferential elements82may be distributed along the length88b,for example, positioned evenly and equidistantly along the length88b,of the second extension portion22between the interior center C and the second distal end23. A third plurality of circumferential elements84may be disposed about the third extension portion24along the length88cof the third extension portion24. The third plurality of circumferential elements84may be distributed along the length88c,for example, positioned evenly and equidistantly along the length88c,of the third extension portion24between the interior center C and the third distal end25. A fourth plurality of circumferential elements86may be disposed about the fourth extension portion26along the length88dof the fourth extension portion26. The fourth plurality of circumferential elements86may be distributed along the length88d,for example, positioned evenly and equidistantly along the length88d,of the fourth extension portion26between the interior center C and the fourth distal end27.

The interior void space16defined by the outer skin14of the portable and collapsible structural element10may be filled or occupied by a filler substance when installed, such that the filler substance is disposed in the interior void space16and in contact with the inwardly facing surface91of the outer skin14.

The filler substance is at least one of a fluid, an aggregate, or a soil. The filler substance may be a viscous fluid such a water; the filler substance may an aggregate material such as sand; the filler substance may be a concrete material; the filler substance may be a soil; or a combination of the foregoing. The type of filler substance may be selected based on the intended use of the structural element10.

For example, if the structural element10is intended for use as an energy-absorbing traffic barrier120, the filler material may be a viscous fluid or foam, if the structural element10is intended for use as an a ballistic defense barrier, the filler material may be a ballistic material, if the structural element10is intended for use as a construction or pedestrian barrier, the filler material may be a viscous fluid, a structural foam, an aggregate, concrete or another substance providing enough weight that the structural element10is not movable by a single person when in the employed or installed position. The filler substance may also comprise a mixture or layered plurality of different filler materials to provide the desired energy management properties. For example, in an energy absorbing traffic barrier120(FIGS. 20A-21), the filler substance may comprise a heavy aggregate, such as sand or the like within the respective extension portions20,22,24,26, of the first bisection32, and a viscous fluid, such as water or the like, may comprise filler substance within the respective extension portions20,22,24,26, of the second bisection30to allow for strength in the first bisection32and energy absorption in the second bisection30.

Once the filler substance is disposed within the interior void space16defined by the outer skin14the access point92may be sealed. In a re-usable example, wherein the filler substance may be drained from the interior void space16within the outer skin14after use and then transported away, the access point92may be sealed via, but not limited to, a cap, a removable adhesive, a tape, an elastic cover, or for example with a further application of a polyurea top coat. In a non-reusable example, the access point92may be sealed via, but not limited to, a cap, thermal bonding, a removable adhesive, a permanent adhesive, a tape, an elastic cover, or for example with a further application of a plug or a coating, such as a polyurea-based top coat.

The portable and collapsible structural element10may be formed and installed via method100disclosed herein and detailed via the flow diagram inFIG. 22. In this way, the portable and collapsible structural element10may be formed using a negative form56(FIGS. 10, 12, 15). As such, at step101a negative form56is provided, wherein the negative form56comprises a form body58,60,62,64, the form body58,60,62,64having an external form surface96and an interior center, the exterior form surface96being divided into a first portion58, a second portion60, a third portion62, and a fourth portion64. The negative form56may be formed of a fiberglass material or another suitable composite, reinforced, or polymer-based structural material and may comprise four mold portions58,60,62,64that collectively make up the form body, namely, three upper mold portions58,60,62one lower mold portion64. The negative mold56and collectively the four mold portions58,60,62,64may further define the external mold surface96.

Further, the negative form56mirrors the form of the structural element10, in that the negative form56further defines a first extension portion20disposed on a first axis A1and extending outwardly from the interior center in a first predetermined direction D1to a first distal end21, the first extension portion20defining a plurality of first extension portion flange members98that extend outwardly therefrom. A second extension portion22is disposed on a second axis A2extending outwardly from the interior center in a second predetermined direction D2to a second distal end23, the second extension portion22defining a plurality of second extension portion flange members98that extend outwardly therefrom. A third extension portion24is disposed on a third axis A3extending outwardly from the interior center in a third predetermined direction D3to a third distal end25, the third extension portion24defining a plurality of third extension portion flange members98that extend outwardly therefrom. A fourth extension portion26is disposed on a fourth axis A4extending outwardly from the interior center in a fourth predetermined direction D4to a fourth distal end27, the fourth extension portion26defining a plurality of fourth extension portion flange members98that extend outwardly therefrom. Each of the first axis A1, the second axis A2, the third axis A3, and the fourth axis A4defines an angle with each of the other axes at the interior center, and wherein the angle between each of the respective axes is substantially equivalent. In this way, the exterior mold surface96defines the interior void space16of the outer skin14.

At step102, optionally, the negative mold56may be covered with a mesh70, as shown by example inFIG. 15, such that the mesh70is in contact with external mold surface96. The mesh70may have varying cell size and configuration. The mesh is designed to allow the outer skin14material to be applied to the external mold surface96without adhering to the negative mold56. In one example, the mesh70is a metallic or wire mesh. Other mesh materials may be used, including, for example, the mesh70can be a polymeric-based mesh, such as a molded or woven plastic mesh, a textile-based mesh such as a woven or knotted fabric or rope mesh, or the like.

At step103, again optionally, in embodiments wherein the structural element10comprises a reinforcing structure54, a reinforcing structure54for the outer skin14is disposed upon each of the first extension portion20, the second extension portion22, the third extension portion24, and fourth extension portion26of the negative form54and in contact with the mesh70. In such instances, the reinforcing structure54may further comprise a plurality of circumferential elements80,82,84,86positioned in contact with the mesh70and the inwardly facing surface91of the outer skin14at each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin14. Further, as detailed hereinabove, each of the circumferential elements80,82,84,86may comprise a textile element alone, a fiberglass element wrapped with the textile material, or the like.

At step104, a polyurea-based material is applied to the external mold surface96of each of the first portion58, the second portion60, the third portion62, and the fourth portion64of the negative form56until the polyurea-based material has a thickness95of greater than 0.125 inches on each of each of the first portion58, the second portion60, the third portion62, and the fourth portion64, such that the polyurea-based material forms the outer skin14of a structural element10. In one example, the polyurea-based material is sprayed onto the external mold surface96of the negative mold56.

More particularly, first a primer applied or sprayed on to the external mold surface96of the negative mold56; one commercially available example primer is the VersaFlex VF 20 primer. Then, a performance-based polyurea basecoat is applied or sprayed over the primer; one commercially-available performance basecoat is the VersaFlex FSS 45DC, which is a one hundred percent solids, plural-component, aromatic-based polyurea elastomer system. This example elastomer system passes ASTM C 1305. Finally, a polyurea-based topcoat is then applied or sprayed on to the base coat; one commercially-available performance topcoat is an aliphatic polyurea system such as the VersaFlex GelFlex 1115 system, which is a plural-component, one hundred percent solids, aliphatic polyurea.

In some examples, the polyurea-based material may be sprayed onto the external mold surface96of each of the mold portions58,60,62,64, in sections, such that the polyurea-based material sprayed on the external mold surface96of the first upper mold portion58to form a first outer skin portion14A, the polyurea-based material sprayed on the external mold surface of the second upper mold portion60to form a second outer skin portion14B, the polyurea-based material sprayed on the external mold surface96of the third upper mold portion62to form a third outer skin portion14C, and the polyurea-based material is sprayed on the external mold surface96of the lower mold portion64to form the fourth outer skin portion14D. In this way, the polyurea-based material is sprayed onto the negative mold94such that the negative mold occupies the interior void space16of the structural element10while the polyurea-based material cures or dries.

As such, at step105, a curing or drying process for the polyurea-based material of the outer skin14is initiated. Upon completion of the curing or drying process for the polyurea-based material, at step106, each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin14are removed from the negative form56.

The lightweight and collapsible nature of the outer skin14of the portable and collapsible structural element10allows for ease of transport, shipping, and installation. As such, optionally, at step107, each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin and the integral reinforcement structure54may be packaged for shipping to a desired installation location along with a coupling feature such as an adhesive, resin binder, epoxy, or another suitable coupling material sufficient in strength to fixedly attach each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin upon set-up and installation. Said another way, the polyurea-based outer skin14along with the reinforcing structure54is fully portable and collapsible such that, the structural element10may exist in one of a collapsed transport condition and an employed or installed condition. Once the outer skin14is cured and fully formed, the respective portions14A,14B,14C,14D of the outer skin may be removed from the negative mold56and packaged along with the reinforcement structure54and a coupling feature and transported or shipped in a condensed configuration, namely in the collapsed transport condition. More particularly, the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin, the integral reinforcing structure54, and the coupling feature may be packaged together in a shippable and easily transportable structural element kit and at step108, shipped or transported to a destination anywhere in the world for set-up, installation, and use.

Upon arrival at the destination, at step109, each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin and the integral reinforcement structure54and the coupling feature may be removed from the structural element kit.

At step110, the end user or installation crew shall select an installation location and orientation for each of the respective structural elements10, such that the plurality of structural elements120forms an elongated mound to serve in various applications, such as a jetty, a breakwater, a pedestrian barrier, a vehicular barrier, an anti-tank obstacle, a ballistic barrier, a construction barrier, an eco-barrier for erosion control, or another form of traversal impediment. Said another way, at step110, each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14dof the outer skin of a first structural element10is positioned in the selected installation location, and then each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14dof the outer skin of each subsequent structural element10is positioned in the selected installation location.

Once the installation location and orientation for each of the structural elements10is selected, the respective the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin and the integral reinforcement structure54may be positioned in the field and transformed from the collapsed transport condition and an employed or installed condition. In this way, at step111, the connection edges99formed along the outer periphery41(FIGS. 16-17) of each of the first portion14A, the second portion14B, the third portion14C, and the fourth portion14D of the outer skin of a respective structural element10to the connection edges99formed along the outer periphery41of at least one of the other respective portions14A,14B,14C,14D of the outer skin of the same respective structural element10with the connection feature, e.g, adhesive, resin binder, epoxy, or the like. The respective portions14A,14B,14C,14D of the outer skin may be glued together or coupled with an epoxy or adhesive at the connection edges99. In one example, the respective portions14A,14B,14C,14D of the outer skin may be fastened together or coupled using mechanical fasteners, such as fastening strips, plastic rivets, etc.

At step112, a curing or drying process for the adhesive, epoxy, or resin binder is initiated. Additionally, the respective portions14A,14B,14C,14D of the outer skin may be coupled with an epoxy or adhesive binder and further secured with clamps until the epoxy or adhesive binder is fully dried or cured.

Once the respective portions14A,14B,14C,14D of the outer skin14are secured to one another, at step113, the interior void space16defined by the outer skin may be filled with a filler substance. Upon filling the structural element10with the filler substance the structural element10transitions to occupy the employed or installed condition. As shown by example inFIG. 17, the outer skin14may be filled with filler substance via the access point92. In a re-usable example, wherein the filler substance may be drained from the interior void space16within the outer skin14after use and then transported away, the access point92may be sealed via, but not limited to, a cap, a removable adhesive, a tape, an elastic cover, or for example with a further application of a polyurea top coat. In a non-reusable example, the access point92may be sealed via, but not limited to, a cap, thermal bonding, a removable adhesive, a permanent adhesive, a tape, an elastic cover, or for example with a further application of a polyurea top coat.

The filler substance may include, at least one of a fluid, an aggregate, or a soil. The filler substance may be a viscous fluid such as water; the filler substance may be an aggregate material such as sand; the filler substance may be a concrete material; the filler substance may be a ballistic or ballistic slag material, or the filler substance may be a soil. The type of filler substance may be selected based on the intended use of the structural element10. For example, if the structural element10is intended for use as an energy-absorbing traffic barrier120, the filler material may be a viscous fluid or a combination of an aggregate and viscous fluid, if the structural element10is intended for use as a ballistic defense barrier, the filler material may be a ballistic material, if the structural element10is intended for use as a construction or pedestrian barrier, the filler material may be a viscous fluid, an aggregate, concrete or another substance providing enough weight that the structural element10is not movable by a single person when in the employed position. The filler substance may also comprise a mixture or layered plurality of different filler materials to provide the desired energy management properties. For example, in an energy absorbing traffic barrier120(FIGS. 20A-21), the filler substance may comprise a heavy aggregate, such as sand or the like within the respective extension portions20,22,24,26, of the first bisection32, and a viscous fluid, such as water or the like, may comprise filler substance within the respective extension portions20,22,24,26, of the second bisection30to allow for strength in the first bisection32and energy absorption in the second bisection30. The examples are illustrative, such that the use of other energy absorbing materials, such as foam, foam composites, polymeric materials, etc., are anticipated within the scope of the disclosure.

In addition to the structural applicability of the portable and collapsible structural elements10as a traffic barrier, in a water management or erosion control context, the portable and collapsible structural barriers10comprising an outer skin14, provide significant improvements over existing solid-state barriers that require difficult transport by barge. In one such instance, the plurality of portable and collapsible structural barriers120may be formed as one of a jetty, a breakwater, or an erosion control apparatus positioned in shallow areas of a body of water. In this way, the portions of the outer skin14A,14B,14C, and14D may be coupled and assembled on land and then positioned in shallow portions of a body of water, e.g., less than three to four feet of depth, that cannot be reached by barge, and then filled with filler material on site after being placed in the body of water.

In such applications, the plurality of structural elements100may be positioned in the form of an elongated mound120. The elongated mound120may comprise a front sloping side wall facing seaward, a rear sloping side wall facing landward, and the plurality of structural elements120covering the seaward slope. Each structural element10of the plurality120is interlocked with at least one other structural element10, the respective extension portions20,22,24,26define void spaces therebetween. The void spaces cooperate to provide a substantial volume of void spaces between the plurality of structural elements120, such that the void spaces are large enough to allow water to pass through the elongated mound120, so that the plurality of structural elements120maintains a high degree of permeability to water and maintains stability under wave action and hydraulic roughness. As such, the volume of void spaces between the plurality of structural elements120is still small enough to allow trap sediment to collect under and within the plurality of structural elements120to mitigate erosion.

As detailed herein, the structural element10may be a solid-state structural element10comprised of a predetermined moldable, formable, and/or curable material, for example, a concrete material, a ballistic material, or the like, a solid-state structural element10comprised of a plurality of aggregate pieces bonded by an adhesive, or the structural element10may be the collapsible and portable formation, standing alone or in a plurality thereof120may be used in various applications, such as a jetty, a breakwater, a pedestrian barrier, a vehicular barrier, an anti-tank obstacle, a ballistic barrier, a construction barrier, an echo or acoustic barrier, or another form of traversal impediment or energy absorbing device.

As shown by example inFIGS. 18-21, the plurality of structural elements120may comprise a series of structural elements10, wherein the structural elements10are randomly organized and stacked, such that the respective extension portions20,22,24,26of the structural elements10are interlocked with one another. The respective extension portions20,22,24,26of each of the structural elements10are configured to receive and interlock with the extension portions20,22,24,26of each of the other structural elements10of the plurality of structural elements120. The plurality of structural elements100may be organized in an elongated mound configuration having a first side118and a second side119.

As shown by example inFIGS. 20A-21, wherein the plurality of structural elements120comprises a traffic barrier, namely, one of a pedestrian barrier, crowd control device, a vehicular barrier, a construction barrier, defensive barrier, anti-tank obstacle, or other traversal impediment, the plurality of the structural elements120may be positioned in an elongated and substantially linear configuration as shown inFIGS. 18, 19, and 20C, or for example, in a curvilinear configuration. Alternatively, the structural elements120may be positioned in a non-linear or randomized grouping, for example, stacked and intermingled as shown by example inFIGS. 20A-20B, 20D, and 21. For example, an elongated mound of structural elements10may be configured to prevent the passage of a pedestrian from a first side118to a second side119. In another example, the elongated mound120may be configured to prevent the passage of a vehicle, such as a tank or an automobile, from the first side118to the second side119. In an example, wherein the structural elements10are formed of a ballistic material, the elongated mound120may be configured to prevent the passage of a ballistic projectile, from the first side118to the second side119.

In any configuration of the plurality120, as shown by example inFIGS. 20A-20D, the plurality of structural elements120may be stacked or intermingled such that the respective extension portions20,22,24,26of each of the structural elements10are configured to receive and interlock with the extension portions20,22,24,26of each of the other structural elements10of the plurality of structural elements120. In such an example, each structural element10is interlocked with at least one other structural element10.

In a pedestrian barrier or construction barrier embodiment, wherein the structural elements10are positioned in an elongated and substantially linear plurality120, such that the plurality of structural elements120is configured to prevent the passage of a pedestrian from a first side118to a second side119of the plurality of structural elements120. In such examples, the structural elements10may be configured to serve as bases for signage and signals (FIG. 21) indicating road or sidewalk closures or other restricted areas. In the construction barrier, pedestrian barrier, or crowd control device application, the filler material may be one of concrete, aggregate such as sand, a viscous fluid such as water, or a ballistic material.

Referring toFIGS. 18-21, the structural element10and a plurality120thereof has industrial applicability as a vehicle barrier. As shown inFIG. 18, the plurality of the structural elements10may be positioned in an elongated and substantially linear configuration, e.g., and elongated mound120, or stacked or intermingled as shown inFIG. 19, such that the respective extension portions20,22,24,26of each of the structural elements10are configured to receive and interlock with the extension portions20,22,24,26of each of the other structural elements10of the plurality of structural elements120. In a vehicular barrier application, the structural elements10are configured to prevent, impede, or slow the passage of a vehicle from the first side118to the second side119of the plurality of structural elements120. In one example application, as shown inFIGS. 20A-21, the vehicle barrier120may be configured to slow the vehicle and/or absorb energy from the vehicle while mitigating damage to the vehicle, for example, as an exit ramp or road median energy absorption system (FIG. 21).

The geometry of the structural elements10as defined herein allows for four potential outcomes upon a vehicle making contact with the structural elements10, namely, the plurality of structural elements120may trap, cradle, or safely decelerate the vehicle (FIGS. 20A-20C), tilt the vehicle (FIG. 20D), or impinge the underside of the vehicle (FIGS. 20A and 20E) depending on the angle of contact. Referring back toFIGS. 1-8BandFIG. 20E, the geometry of the structural element10may define the type of outcome upon a vehicle making contact with the structural elements10. For example, the first cross-sectional diameter48may be designed such that a vehicle cannot climb over (FIG. 20E) the respective extension portion20,22,24,26. In such instances, the vehicle may be stopped in a direction substantially orthogonal to its direction of motion or inertia. In such examples, the angle53is smaller, as the difference between the first cross-section diameter48and the interior base cross-sectional diameter51is smaller or less pronounced.

Alternatively, the first cross-sectional diameter48may be designed such that a vehicle may climb over (FIG. 20E) the respective extension portion20,22,24,26, e.g., at bumper height, to induce an impingement outcome (FIG. 20A, 20E) or a tilt outcome (FIG. 20D). In such examples the angle53is greater, as the difference between the first cross-section diameter48and the interior base cross section diameter51is greater or more pronounced. In an impingement outcome, if contact is made at the precise angle of entry, the structural element10may high center the vehicle thereby impinging the underside of the vehicle and immobilizing the same (20E). In an impingement scenario, the example structural element10shown inFIGS. 5-9Amay be particularly useful in that its pointed polygonal edges may be most effective in an impingement scenario to decelerate and immobilize the vehicle.

Additionally, the overall height17of the structural element10may be designed to prevent movement from one resting position34,36,38,40to another resting position34,36,38,40so that a vehicle cannot climb over the respective extension portion20,22,24,26. In such instances, the extension portion20,22,24,26within the second bisection30may have a length88a,88b,88c,88dthat is substantially shorter than the lengths of each of the extension portions20,22,24,26within the first bisection32, such that the vehicle may be stopped in a direction substantially orthogonal to its direction of motion or inertia.

Alternatively, the overall height17of the structural element10may be designed to facilitate movement from one resting position34,36,38,40to another resting position34,36,38,40when the structural element10is contacted. In such examples, the extension portion20,22,24,26within the second bisection30may have a length88a,88b,88c,88dthat is substantially longer than the lengths of each of the extension portions20,22,24,26within the first bisection32, to facilitate toppling of the structural element10and induce an impingement outcome on the vehicle, if contact is made at the precise angle of entry, to high center the vehicle (20E) thereby impinging the underside of the vehicle and immobilizing the same.

In the vehicle barrier application, the filler material may be one of concrete, aggregate such as sand or the like, a viscous fluid such as water or the like, or a ballistic material, or another substance providing enough weight that the structural element10is not movable by a single person when in the employed position. The filler substance may also comprise a mixture or layered plurality of different filler materials to provide the desired energy management properties (FIGS. 19 and 21). For example, in an energy absorbing traffic barrier (FIG. 21), the filler substance may comprise a heavy aggregate, such as sand or the like within the respective extension portions20,22,24,26, of the first bisection32, and a viscous fluid, such as water or the like, may comprise filler substance within the respective extension portions20,22,24,26, of the second bisection30to allow for strength in the first bisection32and energy absorption in the second bisection30.

In examples wherein a concrete or aggregate material is utilized as the filler material, the plurality of structural elements120may be configured as a vehicle barrier or impediment. As shown by example inFIGS. 20A-20D, the plurality of structural elements120may be stacked or intermingled such that the respective extension portions20,22,24,26of each of the structural elements10are configured to receive and interlock with the extension portions20,22,24,26of each of the other structural elements10of the plurality of structural elements120. In an example such as those shown inFIGS. 19 and 20A-20Ethe structural elements10, when interlocked maintain the ability to tumble from one resting position34,36,38,40to another resting position34,36,38,40while intermingled, upon receiving a force, such as when absorbing energy from and decelerating a vehicle, such as an automobile.

In examples wherein a viscous fluid is utilized as the filler material, the plurality of structural elements120may be configured as a vehicle barrier or energy absorbing structure. As shown by example inFIGS. 20A-20D, the plurality of structural elements120may be stacked or intermingled such that the respective extension portions20,22,24,26of each of the structural elements10are configured to receive and interlock with the extension portions20,22,24,26of each of the other structural elements10of the plurality of structural elements120. In an example such as those shown inFIGS. 19 and 20A-20E, the structural elements10, when interlocked maintain the ability to tumble from one resting position34,36,38,40to another resting position34,36,38,40while intermingled, upon receiving a force, such as when absorbing energy from and decelerating a vehicle, such as an automobile.

Further, in a roadway, vehicular, construction, or crowd control context, the collapsibility and portability of the portable and collapsible subject structural barriers10comprising an outer skin14, provides significant improvements over existing solid-state barriers that are extremely heavy and difficult to transport, place, and position. In one particular application, the plurality of structural elements120may be configured as an energy absorbing device at the entrance to a low-speed highway off ramp114, such as a clover leaf style off ramp (FIG. 21), on the open end portion116of a highway barrier (FIG. 21), as a median divider between opposing traffic lanes, or on other various potentially-hazardous road markings, obstacles, or encumbrances. Utilizing a viscous fluid or foam as a filler material or a viscous fluid, foam and/or aggregate combination of filler materials, allows the structural elements10to roll, tumble and interlock with one another upon contact and move from one resting position34,36,38,40to another. This ability to tumble and interlock provides improvements over the existing applications for these purposes having a viscous fluid filler material, in that the structural elements described herein will tumble and interlock rather than burst. Further, the viscous fluid filler material is more elastic and permeable than a concrete or aggregate, which allows the plurality of structural elements120to absorb the energy from and safely decelerate the subject vehicle before ultimately trapping, cradling, or safely, tilting, or impinging the vehicle upon rest.

In examples wherein, a ballistic material is utilized as the filler material, the plurality of structural elements120may be configured as an anti-tank obstacle or other ballistics impediment, and may be positioned in an elongated and substantially linear configuration (FIG. 18) or stacked or intermingled as shown in (FIG. 19). In this way, the ballistic resistance of the filler material may protect against the passage of projectiles from the first side118to the second side119. Further, the geometry of the structural elements10as detailed herein allows the structural elements10, namely, the plurality of structural elements120to trap the oncoming tank (FIG. 20A-20C), tilt the oncoming tank (FIG. 20D), or impinge the underside of the oncoming tank (FIGS. 20A and 20E) depending on the angle of contact. In any case, the plurality of structural elements120shall prevent the oncoming tank from passing from the first side118to the second side119thereof.

The examples described herein are non-limiting, and it would be understood that the structural elements10can be arranged into a plurality of structural elements120to define a structural barrier120having a shape or size other than the examples shown in the Figures. For example, a plurality of structural elements120may be arranged to at least partially surround another structure or object to be protected or barricaded, where the protected object may be, for example, a building, statue, designated area of land or portion of roadway, or a transient object moving proximate to the structural barrier120, such as a motorcade, parade, group of persons, or the like. For example, a plurality of structural elements120may be fastened to each other, via chain, rope or other means, to prevent or impede separation of one of the structural elements10from another when subjected to loading, for example, from a colliding force or ballistic force.