A method for repairing a composite structure, includes creating a repair cavity in a composite structure, placing foamable media in the repair cavity, placing a replacement skin over the repair cavity, and expanding the foamable media placed in the repair cavity.

A method for repairing a composite structure, includes creating a repair cavity in a composite structure, placing foamable media in the repair cavity, placing a replacement skin over the repair cavity, and expanding the foamable media placed in the repair cavity.

A pressure tool for rotor blade repair including a mobile support system including a support surface, a first bladder support assembly including a first inflatable bladder fixedly mounted to the support surface, a second bladder support assembly including a second inflatable bladder pivotally mounted relative to the support surface, and an activation mechanism operatively coupled to the second bladder support assembly. The activation mechanism is operable to selectively shift the second bladder support assembly relative to the first bladder support assembly. A fluid delivery system is operable to direct a fluid into each of the first inflatable bladder and the second inflatable bladder.

A pressure tool for rotor blade repair including a mobile support system including a support surface, a first bladder support assembly including a first inflatable bladder fixedly mounted to the support surface, a second bladder support assembly including a second inflatable bladder pivotally mounted relative to the support surface, and an activation mechanism operatively coupled to the second bladder support assembly. The activation mechanism is operable to selectively shift the second bladder support assembly relative to the first bladder support assembly. A fluid delivery system is operable to direct a fluid into each of the first inflatable bladder and the second inflatable bladder.

A method of repairing a defect of a thermoplastic component is provided. The thermoplastic component has a thermoplastic material at the defect having a first melting temperature, and the defect has a contact surface (TC contact surface). The method includes a) providing a patch comprising a second thermoplastic material having a second melting temperature that is below the first melting temperature. The patch includes a contact surface (TP contact surface); b) disposing a portion of a heating element between the TC contact surface and the TP contact surface. The heating element is operable to heat up as a result of electrical resistance; c) forcing the TP surface toward the TC surface; and d) inputting energy into the heating element to cause the heating element to heat and maintain the TP surface at or above the second melting temperature to produce bonding between the thermoplastic component and the patch.

A system for repairing polymer structures, for example, polypropylene storage tanks for liquid, includes the application of a unique primer in connection with a plurality of layers of other adhesives to attach a liquid-impermeable elastomeric liner. The system permits the liquid-impermeable elastomeric liner to expand and contract along with the polymer tank, thus resisting separation of the liner from the polymer.

A drive shaft has a central tubular portion formed of a polymer composite with imbedded fibers. It extends between a first end and a second end. The central tubular portion has an outer peripheral surface. There is at least one ring on the outer peripheral surface of the central tubular portion. A method of repairing a composite material tube includes the steps of (a) identifying a damaged area on a composite tube, and (b) placing a patch on a surface of the tube and over the damaged area.

A drive shaft has a central tubular portion formed of a polymer composite with imbedded fibers. It extends between a first end and a second end. The central tubular portion has an outer peripheral surface. There is at least one ring on the outer peripheral surface of the central tubular portion. A method of repairing a composite material tube includes the steps of (a) identifying a damaged area on a composite tube, and (b) placing a patch on a surface of the tube and over the damaged area.

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.

Methods and apparatus for performing repair operations using an unmanned aerial vehicle (UAV). A UAV carries a repair patch ensemble containing all repair materials (including a repair patch, a heating blanket and other ensemble materials) in a prepackaged form to the repair area. During flight of the UAV, the repair patch is vacuum adhered to the heating blanket. Vacuum pressure is also used to hold the repair patch ensemble in position on the composite surface of the structure. Then the hot bond process is enacted to bond the repair patch to the repair area. In accordance with one embodiment, the hot bond process involves heating the repair patch to adhesively bond the repair patch while applying vacuum pressure to consolidate the composite material. Then the repair patch is released from the ensemble and residual ensemble materials (heating blanket, bleeder material, and release films) are removed by the UAV.