Composite reinforcement systems and methods of manufacturing the same
Systems and methods for reinforcing physical structures with composite reinforcement systems are disclosed herein. According to aspects of the present disclosure, a composite reinforcement system includes a carrier formed of a plurality of fibers and a blend of at least two reagents impregnated within the carrier. The at least two reagents are chemically configured to react to form a moisture-curable prepolymer. One reagent of the at least two reagents is an isocyanate, and another reagent of the at least two reagents is an aromatic-group-containing polyol.
1. A composite reinforcement system comprising:
a carrier made of a plurality of fibers; and
a moisture-curable prepolymer impregnating the carrier in a partially cured state, the moisture-curable prepolymer formed of at least a polyfunctional aliphatic isocyanate and an aromatic-group-containing polyol as the only polyol;
wherein the polyfunctional aliphatic isocyanate is an isocyanurate-based polyfunctional isocyanate with an isocyanate functionality of greater than two,
the carrier is a fabric or includes unidirectional fiber layers therein,
the aromatic-group-containing polyol is based on a polymer selected from polyester, polyamide, polyurethane, polyurea, and a combination thereof and has aromatic groups in its backbone,
wherein the polyfunctional aliphatic isocyanate includes about 50 wt. % to 90 wt. % of the moisture-curable prepolymer, and the aromatic-group-containing polyol constitutes about 10 wt. % to 50 wt. % of the moisture-curable prepolymer, and
wherein the composite reinforcement system is packed in a moisture-tight enclosure.
2. The composite reinforcing system of claim 1 , further comprising a filler in the moisture-curable prepolymer, the filler selected from the group consisting of wollastonite, halloysite, chopped glass, boron nitride, boron carbide, silicon carbide, tungsten carbide, aluminum oxide, fumed silica, chopped carbon fiber, and a combination thereof.
3. The composite reinforcing system of claim 1 , wherein a ratio of the carrier to the moisture-curable prepolymer between about 40:60 to about 60:40 by weight.
4. The composite reinforcing system of claim 1 , wherein the aromatic-group-containing polyol is polyester-based and includes aromatic groups in its backbone allowing for pi-pi stacking.
5. The composite reinforcement system of claim 1 , wherein the plurality of fibers are selected from carbon fibers, glass fibers, basalt fibers, liquid crystalline polyester fibers, aramid fibers, metal fibers, and a combination thereof.
6. The composite reinforcing system of claim 1 , wherein the plurality of fibers include carbon fibers extending in a 0 degree direction and fiberglass fibers in a 90 degree direction, and the carbon fibers constitute at least about 70 wt % of the carrier and the fiberglass fibers constitute at most about 30 wt % of the carrier.
7. A method of making the composite reinforcing system of claim 1 , comprising forming a prepreg for the composite reinforcement system, wherein the forming the prepreg comprises:
forming a blend of at least two reagents chemically configured to react to form the moisture-curable prepolymer;
impregnating the carrier with the blend of the at least two reagents; and
while within the carrier, allowing the at least two reagents impregnated within the carrier to react to form the moisture-curable prepolymer.
8. The method of claim 7 , further comprising:
applying a film on one side of the prepreg;
rolling the prepreg around a core to form a prepreg roll, with adjacent layers of the prepreg within the prepreg roll being separated by the film; and
packaging the prepreg roll in a moisture-tight container.
9. A method of using the composite reinforcing system of claim 1 for reinforcing a surface, comprising:
removing the composite reinforcement system from a protective packaging;
applying the composite reinforcing system to the surface; and
allowing the moisture-curable prepolymer to cure and harden upon exposure to moisture.
10. A composite reinforcement system comprising:
a carrier and a resin, the carrier saturated with the resin, the resin including a prepolymer formed of at least a polyfunctional aliphatic isocyanate and an aromatic-group-containing polyol as the only polyol and being chemically configured to harden upon exposure to moisture,
wherein the polyfunctional aliphatic isocyanate is an isocyanurate-based polyfunctional isocyanate with an isocyanate functionality of greater than two,
the carrier is a fabric or includes unidirectional fiber layers therein, and
the aromatic-group-containing polyol is based on a polymer selected from polyester, polyamide, polyurethane, polyurea, and a combination thereof and has aromatic groups in its backbone,
wherein the polyfunctional aliphatic isocyanate constitutes about 50 wt. % to 90 wt. % of the moisture-curable prepolymer, and the aromatic-group-containing polyol constitutes about 10 wt. % to 50 wt. % of the moisture-curable prepolymer, and
wherein the composite reinforcement system is stored in a moisture-tight enclosure.
11. The composite reinforcement system of claim 10 , wherein the plurality of fibers comprises carbon fibers, glass fibers, and a combination thereof.
12. The composite reinforcing system of claim 10 , wherein a ratio of the carrier to the resin between about 40:60 to about 60:40 by weight.
13. A method of making the composite reinforcing system of claim 10 , comprising forming a prepreg for the composite reinforcement system by
forming a blend of at least two reagents chemically configured to react to form the prepolymer; and
impregnating the carrier with the blend of the at least two reagents.
14. A method of using the composite reinforcing system of claim 10 for reinforcing a surface of a physical structure, comprising:
applying the composite reinforcing system to the surface; and
allowing the prepolymer to cure and harden upon exposure to moisture.
15. The method of claim 14 , wherein the physical structure is selected from the group consisting of a pipe, a tank, a concrete beam, a concrete slab, a concrete column, a concrete square, a metal structure, a wall, and a floor slab.
16. The method of claim 14 , wherein the physical structure is a pipeline, and the composite reinforcement system is wrapped around a pipeline assembly in one or more overlapping layers.