High strength and high elasticity composite materials and methods of reinforcing substrates with the same

Abstract

In accordance with various embodiments of the disclosed subject matter, a composite material is provided. The composite material in accordance with some embodiments of the disclosed subject matter includes a high tenacity fiber reinforced polymer fabric and a polyurea coating layer formed on at least one surface of the polymer fabric. The composite material provides significant strength, flexibility, and energy dissipation. In some embodiments, the composite material can be used to reinforce structural and non-structaral substrates.

What is claimed is: 
     
         1 . A composite comprising:
 a substrate;   a fiber reinforced polymer fabric layer attached to at least a portion of the substrate; and   a polyurea coating layer formed on an exposed surface of the fiber reinforced polymer fabric layer.   
     
     
         2 . The composite of  claim 1 , wherein the substrate is at least one of: wood, masonry, concrete, steel, and a combination thereof. 
     
     
         3 . The composite of  claim 1 , wherein the substrate has at least one damaged portion and the fiber reinforced polymer fabric layer and the polyurea coating layer are formed on the at least one damaged portion of the substrate. 
     
     
         4 . The composite of  claim 1 , wherein the fiber reinforced polymer fabric layer is a carbon fiber reinforced polymer fabric. 
     
     
         5 . The composite of  claim 1 , wherein the polyurea coaling layer is formed by applying an elastomeric polyurea-forming component solution to the exposed surface of the fiber reinforced polymer fabric layer, wherein the elastomeric polyurea-forming component solution forms an aromatic polyurea coating layer. 
     
     
         6 . The composite of  claim 1 , wherein the polyurea further comprises an additive component, wherein the additive component is at least one of: an ultraviolet (UV) protective additive, a flame retardant, a corrosion, protective additive, a moisture resistance additive, ceramic microspheres, and a combination thereof. 
     
     
         7 . A method for reinforcing a substrate, the method comprising:
 providing a substrate;   attaching a high tenacity fiber reinforced polymer fabric to at least a portion of the substrate;   applying a saturant composition to an exposed surface of the high tenacity fiber reinforced polymer fabric, wherein the saturant composition comprises a polymer resin;   curing the saturant composition to form a tacky surface;   applying an elastomeric polyurea-forming component solution, to the tacky surface; and   curing the polyurea-forming component solution to form, a polyurea coating layer.   
     
     
         8 . The method of  claim 7 , wherein the substrate is at least one of: wood, masonry, concrete, steel, and a combination thereof. 
     
     
         9 . The method of  claim 7 , wherein the saturant composition is cured for a first time period and wherein the polyurea-forming component solution is cured for a second time period, the method further comprising modifying the first time period and the second time period to obtain material properties of the polyurea coating layer on the high tenacity fiber reinforced polymer fabric. 
     
     
         10 . The method of  claim 7 , further comprising performing surface preparation on at least a portion of the substrate, wherein the surface preparation includes at least one of: smoothing the substrate, filling in one or more damaged portions of the substrate with a putty material, and cleaning the substrate. 
     
     
         11 . The method of  claim 7 , wherein the high tenacity fiber reinforced polymer fabric is wrapped around the substrate. 
     
     
         12 . The method of  claim 7 , wherein the polyurea-forming component solution comprises an isocyanate component and a polyamine component the method further comprising mixing the isocyanate component and the polyamine component prior to the applying to the tacky surface to form the polyurea-forming component solution, wherein the polyurea-forming component solution has an excess of the isocyanate component. 
     
     
         13 . The method of  claim 7 , further comprising spraying the polyurea-forming component solution on the tacky surface. 
     
     
         14 . The method of  claim 7 , further comprising providing an additive component into the polyurea-forming component solution, wherein the additive component is at least one of: an ultraviolet (UV) protective additive, a flame retardant, a corrosion protective additive, a moisture resistance additive, ceramic microspheres, and a combination thereof. 
     
     
         15 . The method of  claim 7 , wherein the polyurea coating layer has a thickness, the method further comprising controlling the thickness of the polyurea coating layer. 
     
     
         16 . The method of  claim 7 , wherein at least a first component of the polyurea-forming component solution and a second component of the tacky surface of the saturant composition applied to the high tenacity fiber reinforced polymer fabric interact to form an sustainable interface between the polyurea coating layer and the high tenacity fiber reinforced polymer fabric. 
     
     
         17 . A method for providing a composite, the method comprising:
 forming a polyurea-coated high tenacity fiber reinforced polymer fabric, wherein the forming comprises:
 providing a high tenacity fiber reinforced polymer fabric; 
 applying a saturant composition to a surface of the high tenacity fiber reinforced polymer fabric, wherein the saturant composition comprises a polymer resin; 
 curing the saturant composition to form a tacky surface; 
 applying an elastomeric polyurea-forming component solution to the tacky surface; and 
 curing the polyurea-forming component solution to form a polyurea coating layer on the high tenacity fiber reinforced polymer fabric. 
   
     
     
         18 . The method of  claim 17 , further comprising:
 preparing at least a portion of a substrate for reinforcement prior to positioning the polyurea-coated high tenacity fiber reinforced polymer fabric on the substrate; and   attaching the polyurea-coated high tenacity fiber reinforced polymer fabric to a damaged portion of the substrate.   
     
     
         19 . The method of  claim 17 , wherein the saturant composition, is cured for a first time period and wherein the polyurea-forming component solution, is cured for a second time period, the method further comprising modifying the first time period and the second time period to obtain the polyurea coating layer of a thickness based at least in part on an assessment of the damaged portion of the substrate. 
     
     
         20 . The method of  claim 17 , wherein at least a first component of the polyurea-forming component solution and a second component of the tacky surface of the saturant composition applied to the high tenacity fiber reinforced polymer fabric interact to form an sustainable interface between tire polyurea coating layer and the high tenacity fiber reinforced polymer fabric.