Reinforced polymer-infused fiber composite repair system and methods for repairing composite materials

A method for repairing a reinforced polymer-infused fiber composite comprising:

• providing a resin infusion device comprising a flexible, sealed resin container containing one or more uncured resin components in one or more separate resin compartments;
• a vacuum enclosure;
• at least one resin conduit;
• at least one vacuum conduit;
• and a vacuum source, wherein the flexible, sealed resin container comprises a first seal separating the one or more resin compartments from the at least one resin conduit and a non-breakable seal of uniform strength extending around the entire periphery of the flexible, sealed resin container to seal the flexible, sealed resin container and secure the at least one resin conduit, the first seal being a breakable or burstable separating seal;
• positioning a dry fiber reinforcement onto a base layer repair location;
• connecting the least one resin conduit from the flexible, sealed resin container to a first end of the dry fiber reinforcement;
• affixing the at least one resin conduit to the base layer repair location;
• connecting the at least one vacuum conduit from the vacuum source to a second end of the dry fiber reinforcement, where the second end of the dry fiber reinforcement is opposite the first end of the dry fiber reinforcement and proximal the periphery of the base layer repair location such that the at least one vacuum conduit terminates over an edge of the dry fiber reinforcement under the vacuum enclosure;
• affixing the at least one vacuum conduit to the base layer repair location;
• covering and sealing the base layer repair location with the vacuum enclosure;
• affixing the vacuum enclosure to the base layer repair location;
• using the vacuum source to create a vacuum environment at the base layer repair location via the at least one vacuum conduit;
• breaking or bursting the first seal to release a reactive mixture of the resin components into the resin tubing;
• and
• infusing the dry fiber reinforcement with the reactive mixture of the resin components under vacuum conditions via the resin tubing to form a resin-infused fiber reinforcement, wherein the resin-infused fiber reinforcement is cured inside the vacuum enclosure.