Described are methods and systems for repair of composite components without the use of vacuum bagging, The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

Described are methods and systems for repair of composite components without the use of vacuum bagging, The systems described herein include a composite repair structure with a repair laminate and a film sealant. The film sealant covers the repair laminate to prevent intrusion of air and other volatiles during bonding of the composite repair structure to the composite being repaired. As the film sealant prevents intrusion of air and other volatiles, the composite repair structure can be bonded to the structure to be repaired without the use of a vacuum bag. Thus, vehicle components can be repaired without disassembly from the vehicle.

A repair for a structural element made from a composite material includes a bracket defining a first surface and a second surface. The first surface is adapted for facing the structural element. A chamfer is located on a first end of the bracket. An angle is defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The repair also includes a sealant material between the bracket and the structural element, where the sealant material occupies a space established between the chamfer and the structural element.

A repair for a structural element made from a composite material includes a bracket defining a first surface and a second surface. The first surface is adapted for facing the structural element. A chamfer is located on a first end of the bracket. An angle is defined between a plane of the chamfer and a plane of the first surface, the first surface of the bracket being adapted to be disposed adjacent to a side of the structural element. The repair also includes a sealant material between the bracket and the structural element, where the sealant material occupies a space established between the chamfer and the structural element.

In an embodiment, a plug formulation includes a mixture of a first part of a two-part epoxy system and artificial platelets formed from a polymeric material that expands upon exposure to ultraviolet (UV) light, moisture, or heat, wherein a portion of the first part of the two-part epoxy system is covalently bonded to a portion of the artificial platelets. In another embodiment, a plug formulation includes a mixture of a first part of a two-part epoxy system, an acrylate monomer, and artificial platelets formed from a polymeric material that expands upon exposure to ultraviolet (UV) light, moisture, or heat, wherein a portion of the first part of the two-part epoxy system is covalently bonded to a portion of the artificial platelets.

Various method for repairing a tire tread are provided. In one embodiment, a method for repairing a tire tread is provided, the method comprising: providing a tire having a tire tread portion, wherein the tire tread portion includes at least one of a tread block and a tread rib, and wherein at least one of the tread block and the tread rib includes a void resulting from wear or damage of the tire tread portion; scanning the void with a 3D scanner to create a 3D computer model of the void; generating a negative of the void via the 3D computer model, the negative corresponding to a positive removed element representing the material removed from the void; 3D printing a removed element copy using a polymer material; applying an adhesive to at least one surface of the void; applying the removed element copy to the void; and curing the adhesive.

In an example, a mandrel for a composite part includes an upper-mandrel portion, a lower-mandrel portion, and a mid-mandrel portion between the upper-mandrel portion and the lower-mandrel portion. The mandrel also includes a cavity and an exterior surface defined by the upper-mandrel portion, the lower-mandrel portion, and the mid-mandrel portion. An actuator is movable in the cavity between a first position and a second position. The exterior surface can support the composite part. A perimeter of the exterior surface has a first length when the actuator is in the first position and the perimeter has a second length when the actuator is in the second position. The first length is greater than the second length such that the mandrel is in an expanded state when the actuator is in the first position and the mandrel is in a contracted state when the actuator is in the second position.

In an example, a mandrel for a composite part includes an upper-mandrel portion, a lower-mandrel portion, and a mid-mandrel portion between the upper-mandrel portion and the lower-mandrel portion. The mandrel also includes a cavity and an exterior surface defined by the upper-mandrel portion, the lower-mandrel portion, and the mid-mandrel portion. An actuator is movable in the cavity between a first position and a second position. The exterior surface can support the composite part. A perimeter of the exterior surface has a first length when the actuator is in the first position and the perimeter has a second length when the actuator is in the second position. The first length is greater than the second length such that the mandrel is in an expanded state when the actuator is in the first position and the mandrel is in a contracted state when the actuator is in the second position.

A tool is configured to have a changeable shape. The tool comprises a thermoplastic polymeric material, resistive heating elements within the thermoplastic polymeric material, and a flexible casing encapsulating the thermoplastic polymeric material and resistive heating elements.

A hot stapler comprises a body, two heat conducting units, an electrical storage unit, a circuit unit, and a switch button. The body includes a head and a handle. The electrical storage unit is disposed in the handle and has a voltage value less than 6 volts. A first wire and a first resistor of the circuit unit are electrically mounted between one of the two heat conducting units and the electrical storage unit. A second wire and a second resistor of the circuit unit are electrically mounted between the other one of the two heat conducting units and the electrical storage unit. The switch button is disposed on the handle and is switchable between a power-on position and a power-off position.