Unidirectional fiber composite system for structural repairs and reinforcement

A composite system for the reinforcement of physical structures, the composite system comprising:

• a plurality of first unidirectional fibers each having a first longitudinal axis and a first length, the plurality of first unidirectional fibers being of approximately equal length and arranged with the respective first longitudinal axes parallel to each other over a substantial portion of the first length of each first unidirectional fiber;
• a plurality of second unidirectional fibers each having a second longitudinal axis and a second length, the plurality of second unidirectional fibers being of approximately equal length and arranged with the respective second longitudinal axes parallel to each other over a substantial portion of the second length of the second unidirectional fibers, the second length being less than the first length;
• and
• a moisture-curable urethane resin material adhering the plurality of first unidirectional fibers to each other such that each of the plurality of first unidirectional fibers is adhered to at least one adjacent one of the plurality of first unidirectional fibers along a substantial portion of the first length of the adjacent first unidirectional fibers thereby forming a first unidirectional fiber layer of non-mechanically connected first unidirectional fibers to define a first plane, the moisture-curable urethane resin material further adhering the plurality of second unidirectional fibers to each other such that each of the plurality of second unidirectional fibers is adhered to at least one adjacent one of the plurality of second unidirectional fibers along a substantial portion of the second length of the adjacent second unidirectional fibers thereby forming a second unidirectional fiber layer of non-mechanically connected second unidirectional fibers to define a second plane,
• wherein the plurality of second unidirectional fibers are oriented such that any one of the second longitudinal axes in the second plane is skew to any one of the first longitudinal axes in the first plane, and wherein the first unidirectional fiber layer and the second unidirectional fiber layer are non-mechanically connected,
• wherein the first unidirectional fiber layer and the second unidirectional fiber layer are non-mechanically connected such that there is no direct connection between the fibers of the two layers, and
• wherein the moisture-curable urethane resin material is configured to adhere and/or bond at least one of the plurality of unidirectional fiber layers to concrete, wood, steel, titanium, brass, bronze, copper, aluminum, or any combination thereof.

A composite system for reinforcement of physical structures, the composite system comprising:

• a first unidirectional fiber layer including a plurality of non-mechanically connected first unidirectional fibers each having a first longitudinal axis and a first length, the plurality of first unidirectional fibers being of approximately equal length and arranged with the respective first longitudinal axes parallel to each other over a substantially the entire first length of each first unidirectional fiber, the plurality of first unidirectional fibers including electrically and/or heat conductive materials, the plurality of first unidirectional fibers being adhered to each other by a moisture-curable urethane resin material such that each of the plurality of first unidirectional fibers is adhered to at least one adjacent one of the plurality of first unidirectional fibers along substantially the entire first length of an adjacent first unidirectional fiber;
• an insulating fiber layer adhered to the first unidirectional fiber layer by the moisture-curable urethane resin material and/or another resinous material;
• and
• a third layer, the third layer being separated from the first unidirectional fiber layer by the insulating fiber layer, the third layer being in contact with the insulating fiber layer, the third layer comprising a primer, a coating, a gel, an insulator, or any combinations thereof, wherein the third layer is adapted to be applied directly to a electrically and/or heat conductive physical structure,
• wherein the insulating layer separates the electrically and/or heat conductive materials in the first unidirectional fiber layer from direct contact with an electrically and/or heat conductive physical structure being reinforced by the composite system.