Kits and methods for fiber composites including partially-cured resinous materials for the reinforcement of physical structures

A repair kit for the reinforcement of a physical structure, comprising:

• a sealed package defining a moisture-tight enclosure;
• a first unidirectional carbon fiber layer including a plurality of first non-mechanically connected unidirectional carbon fibers located within the moisture-tight enclosure, the modulus of elasticity of the first unidirectional carbon fibers being in the range of about 12 Msi to 150 Msi;
• a second fiber layer including a plurality of second fibers located within the moisture-tight enclosure, the second fiber layer overlaying the first fiber layer;
• a resinous material preimpregnating and adhering the plurality of first non-mechanically connected unidirectional carbon fibers to each other such that each of the plurality of first non-mechanically connected unidirectional carbon fibers is adhered to at least one adjacent one of the plurality of first non-mechanically connected unidirectional carbon fibers, the resinous material further preimpregnating the plurality of second fibers, the resinous material adhering the first unidirectional carbon fiber layer to the second fiber layer,
• wherein the resinous material comprises a moisture-curable prepolymer that is stored in a partially-cured state within the moisture-tight enclosure, the moisture-curable prepolymer being configured to be fully-cured in response to the resinous material being exposed to moisture while the first and second fibers are adhered to the physical structure after removal from the sealed package.

A repair kit for reinforcement of a physical structure, comprising:

• a pouch defining a moisture-tight enclosure;
• and
• a plurality of non-mechanically connected unidirectional fibers located within the moisture-tight enclosure, the plurality of non-mechanically connected unidirectional fibers being preimpregnated with a resinous material comprising an aliphatic moisture-curable polyurethane, the resinous material being in a partially-cured state within the moisture-tight enclosure,
• wherein the resinous material, after removal from the pouch, is configured to transition to a fully-cured and hardened polyurethane material in response to exposure to moisture while being adhered to the physical structure.