An installation tool and method are provided to apply a patch to a structure while controlling the porosity in the bond line. An installation tool is provided that includes a frame defining an internal cavity. The installation tool also includes a flexible membrane that divides the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane. The flexible membrane is releasably attached to the patch such that the patch faces the surface. The frame includes first and second vacuum ports into the first and second chambers, respectively, such that pressure therewithin is separately controllable. The pressure within the first and second chambers is controlled such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched to urge the patch toward the surface.

An installation tool and method are provided to apply a patch to a structure while controlling the porosity in the bond line. An installation tool is provided that includes a frame defining an internal cavity. The installation tool also includes a flexible membrane that divides the internal cavity into a first chamber proximate the surface and a second chamber separated from the surface by the first chamber and the flexible membrane. The flexible membrane is releasably attached to the patch such that the patch faces the surface. The frame includes first and second vacuum ports into the first and second chambers, respectively, such that pressure therewithin is separately controllable. The pressure within the first and second chambers is controlled such that the adhesive is degassed while the patch remains spaced from the surface and the flexible membrane is thereafter caused to be stretched to urge the patch toward the surface.

A method for repairing a component constructed in multiple layers from a layer composite material comprises a step of removing material of the layer composite material of the component in the region of damage to the component in order to form a scarfed cutout, such that a scarfed peripheral contour formed from a plurality of layers of the component is formed. Furthermore, fiber-reinforced plastic strips, which exhibit a curable plastic material in an uncured state, are applied in layers in the cutout in order to create a replacement-structure semifinished product that is complementary to and butts against the scarfed peripheral contour of the component. In a further step, the curable plastic material contained in the fiber-reinforced plastic strips is cured in order to create a replacement structure and for joining the replacement structure to the component.

A method for repairing a component constructed in multiple layers from a layer composite material comprises a step of removing material of the layer composite material of the component in the region of damage to the component in order to form a scarfed cutout, such that a scarfed peripheral contour formed from a plurality of layers of the component is formed. Furthermore, fiber-reinforced plastic strips, which exhibit a curable plastic material in an uncured state, are applied in layers in the cutout in order to create a replacement-structure semifinished product that is complementary to and butts against the scarfed peripheral contour of the component. In a further step, the curable plastic material contained in the fiber-reinforced plastic strips is cured in order to create a replacement structure and for joining the replacement structure to the component.

Disclosed is a collapsible heated elastomeric bladder tool for repairing damage to composite structures. The elastomeric bladder tool can be used to repair composite structures in difficult to reach areas, such as under stringers used to stiffen large structures. The elastomeric bladder tool can be inserted into the damaged cavity such as a stringer to support uncured plies during the repair on either surface of the cavity. Integrated heating elements within the elastomeric bladder tool provide heat to cure the plies. The elastomeric bladder tool features a collapsed cross section that facilitates installation and extraction.

Disclosed is a collapsible heated elastomeric bladder tool for repairing damage to composite structures. The elastomeric bladder tool can be used to repair composite structures in difficult to reach areas, such as under stringers used to stiffen large structures. The elastomeric bladder tool can be inserted into the damaged cavity such as a stringer to support uncured plies during the repair on either surface of the cavity. Integrated heating elements within the elastomeric bladder tool provide heat to cure the plies. The elastomeric bladder tool features a collapsed cross section that facilitates installation and extraction.

A system for out of autoclave bonded repairs which including a fixing structure (1) to the composite area to be repaired, including a frame (4) and fixing parts (5, 19) attached to the frame (4), a movable structure (2) able to be attached either to the fixing structure (1) or to the patch manufacturing table (3), which includes three shafts (6, 6, 6) and three engines (7, 7, 7) configured to be able to move the tooling support in the three axes X, Y and Z, and a tooling support of either scanning tool (9), milling tool (10), patch cutting tool (11) or composite patch handle tool (11), and a patch manufacturing structure (3).

A system for out of autoclave bonded repairs which including a fixing structure (1) to the composite area to be repaired, including a frame (4) and fixing parts (5, 19) attached to the frame (4), a movable structure (2) able to be attached either to the fixing structure (1) or to the patch manufacturing table (3), which includes three shafts (6, 6, 6) and three engines (7, 7, 7) configured to be able to move the tooling support in the three axes X, Y and Z, and a tooling support of either scanning tool (9), milling tool (10), patch cutting tool (11) or composite patch handle tool (11), and a patch manufacturing structure (3).

Thermal curing of a potting material within a hole in a surface of a composite material is described utilizing a flexible vacuum compression device that includes a chemical-based heating pack. The vacuum compression device includes an internal compartment within a cavity that retains the chemical-based heating pack, and a vacuum port having a passage into the cavity. An end of the vacuum compression device includes an interface that forms an air-tight seal between the cavity and the surface when applied to a surface of the composite material. Drawing a vacuum via the vacuum port collapses the vacuum compression device and positions the chemical-based heating pack proximate to the surface, enabling heat from the chemical-based heating pack to thermally cure the potting material.

Thermal curing of a potting material within a hole in a surface of a composite material is described utilizing a flexible vacuum compression device that includes a chemical-based heating pack. The vacuum compression device includes an internal compartment within a cavity that retains the chemical-based heating pack, and a vacuum port having a passage into the cavity. An end of the vacuum compression device includes an interface that forms an air-tight seal between the cavity and the surface when applied to a surface of the composite material. Drawing a vacuum via the vacuum port collapses the vacuum compression device and positions the chemical-based heating pack proximate to the surface, enabling heat from the chemical-based heating pack to thermally cure the potting material.