Method of manufacturing a rigid repair wrap including a laminate disposed laterally within the repair wrap

1. A method of manufacturing a repair wrap for repairing or strengthening an item, the method of manufacturing a repair wrap comprising:

providing a fabric, wherein the fabric includes one or more fibers;

creating a film disposed laterally within the fabric by placing the fabric in a liquid polyurethane laminate including monomers that will form a polyurethane film and a solvent, the liquid polyurethane laminate hardening to form the polyurethane film; and

impregnating a hardening material within the fabric, wherein the hardening material is impregnated after the polyurethane film has been created;

wherein the fabric is configured to be wrapped around a portion of an item; and

wherein the hardening material is configured to form a shell about the portion of the item when cured.

2. The method of manufacturing a repair wrap of claim 1 , wherein the one or more fibers include at least one of:

fiberglass fibers;

carbon fiber;

a para-aramid fiber with the molecular formula [—CO—C6H4-CO—NH—C6H4-NH-]n;

aramid fibers;

para-aramid fibers;

basalt fibers;

natural fibers;

polyester; or

nylon.

3. The method of manufacturing a repair wrap of claim 1 , wherein the area density of the fabric is between 180 grams per square meter and 450 grams per square meter.

4. The method of manufacturing a repair wrap of claim 1 , wherein impregnating a hardening material within the fabric includes pressing the hardening material into the fabric using one or more rollers.

5. A method of manufacturing a repair wrap for repairing or strengthening an item, the method of manufacturing a repair wrap comprising:

providing a fabric, wherein the fabric includes:

one or more fibers; and

the one or more fibers are knit to form the fabric;

creating a film disposed laterally within the fabric, the film forming a water tight barrier within the fabric, wherein creating the film includes:

positioning a liquid polyurethane laminate within the fabric, the liquid polyurethane laminate including monomers that will form a polyurethane film and a solvent; and

allowing the liquid polyurethane laminate to solidify into the polyurethane film; and

impregnating a resin within the fabric, wherein the resin is:

impregnated after the film has solidified from the laminate;

water activated;

configured to cure in exposure to air; and

unable to pass through the film;

wherein the fabric is configured to be wrapped around a portion of an item; and

wherein the resin is configured to form a shell about the portion of the item when cured.

6. A method of manufacturing a repair wrap for repairing or strengthening an item, the method of manufacturing a repair wrap comprising:

providing a fabric, wherein the fabric includes:

one or more fibers; and

the one or more fibers are knit to form the fabric;

creating a polyurethane film, wherein the polyurethane film:

is disposed laterally within the fabric;

is parallel to the surface of the fabric; and

forms a water tight barrier within the fabric;

wherein creating the polyurethane film includes:

positioning a liquid polyurethane laminate within the fabric, the liquid polyurethane laminate including monomers that will harden to form the polyurethane film and a solvent; and

solidifying the liquid polyurethane laminate to form the film; and

impregnating a resin within the fabric, wherein the resin is:

impregnated after the film has solidified from the laminate;

disposed on either side of the polyurethane film;

water activated; and

configured to cure in exposure to air;

wherein the polyurethane film remains intact after the resin is impregnated;

wherein the fabric is configured to be wrapped around a portion of an item; and

wherein the resin is configured to form a shell about the portion of the item when cured.

7. The method of manufacturing a repair wrap of claim 5 , wherein the resin includes an additive disposed in the resin.

8. The method of manufacturing a repair wrap of claim 7 , wherein the additive includes at least one of:

plastic;

rubber;

sand;

wood particles;

sawdust;

fibrous material; or

polyester fibrous material.

9. The method of manufacturing a repair wrap of claim 5 , wherein the item comprises at least one of:

wood;

metal;

glass;

plastic;

rubber;

non-biological composites;

fiberglass;

ceramic; or

concrete.

10. The method of manufacturing a repair wrap of claim 5 , wherein the ratio of resin to fabric by weight is between 29 percent and 44 percent.

11. The method of manufacturing a repair wrap of claim 10 , wherein the ratio of resin to fabric by weight is approximately 36.5 percent.

12. The method of manufacturing a repair wrap of claim 6 , wherein the resin includes:

methylene diphenyl diisocyanate.

13. The method of manufacturing a repair wrap of claim 12 , wherein the resin includes:

a two part epoxy.

14. The method of manufacturing a repair wrap of claim 12 , wherein the gauge of the knit fabric is between 11 stitches per inch and 17 stitches per inch.

15. The method of manufacturing a repair wrap of claim 14 , wherein the gauge of the knit fabric is approximately 14 stitches per inch.

16. The method of manufacturing a repair wrap of claim 12 , wherein the polyurethane film includes a dye, the dye configured to change the color of the polyurethane film.

17. The method of manufacturing a repair wrap of claim 12 , wherein the polyurethane film is between 0.1 and 0.2 millimeters thick.

18. The method of manufacturing a repair wrap of claim 12 , wherein creating the polyurethane film includes:

providing a backer paper;

depositing the liquid polyurethane laminate on the backer paper;

pressing the backer paper onto the fabric;

allowing the polyurethane laminate to form the polyurethane film, wherein allowing the polyurethane laminate to form the polyurethane film includes:

allowing the solvent to evaporate; and

removing the backer paper from the knit fabric.