A method and a tool for repairing a composite-material panel of an aircraft with at least one repair part made of composite material without using an autoclave. The repair method includes the steps of preparing the panel, placing at least one repair part made of composite material on the second face to cover a damaged zone, positioning a vacuum bag configured to sealingly cover the repair part, polymerizing or consolidating the repair part, compressing the vacuum bag against the repair part using a compression plate concomitantly with the step in which the repair part is polymerized or consolidated.

A method and a tool for repairing a composite-material panel of an aircraft with at least one repair part made of composite material without using an autoclave. The repair method includes the steps of preparing the panel, placing at least one repair part made of composite material on the second face to cover a damaged zone, positioning a vacuum bag configured to sealingly cover the repair part, polymerizing or consolidating the repair part, compressing the vacuum bag against the repair part using a compression plate concomitantly with the step in which the repair part is polymerized or consolidated.

A method and apparatus for forming a bonded joint on a composite structure is presented. An apparatus carrying a first workpiece is positioned relative to a second workpiece. A vacuum is applied to the first workpiece and a portion of the second workpiece. A bladder on a first surface of a housing of the apparatus is deflated. Deflating the bladder positions the first workpiece such that adhesive having a desired thickness is positioned between the first workpiece and the second workpiece. The adhesive positioned between the first workpiece and the second workpiece is cured.

Methods of repairing a manufacturing defect in a molded polymeric composite structure are provided. A polymeric patch may optionally be disposed over a defect on a first contoured surface of the molded polymeric composite structure having the defect. A heating element that defines a second contoured surface complementary with at least a portion of the first contoured surface is applied over the polymeric patch. The heating element includes an electrically conductive layer that includes a fabric and a thermoset polymer. The polymeric patch is heated with the heating element, where the heating element has a substantially uniform temperature across the second contoured surface so that the polymeric patch fills the defect. Methods of making the customized heating elements and the customized heating elements are also provided.

Methods of repairing a manufacturing defect in a molded polymeric composite structure are provided. A polymeric patch may optionally be disposed over a defect on a first contoured surface of the molded polymeric composite structure having the defect. A heating element that defines a second contoured surface complementary with at least a portion of the first contoured surface is applied over the polymeric patch. The heating element includes an electrically conductive layer that includes a fabric and a thermoset polymer. The polymeric patch is heated with the heating element, where the heating element has a substantially uniform temperature across the second contoured surface so that the polymeric patch fills the defect. Methods of making the customized heating elements and the customized heating elements are also provided.

An apparatus and method for repairing a damaged laminate including the process of cutting out a damaged section and replacing damaged section with a repair laminate, then covering the repair laminate with a vacuum bag having a heater disposed therein. Thereafter, applying heat and pressure to the repair laminate with the heater and vacuum bag to adequately debulk and cure the repair laminate.

An apparatus and method for repairing a damaged laminate including the process of cutting out a damaged section and replacing damaged section with a repair laminate, then covering the repair laminate with a vacuum bag having a heater disposed therein. Thereafter, applying heat and pressure to the repair laminate with the heater and vacuum bag to adequately debulk and cure the repair laminate.

The present invention sufficiently heats a repairing material while preventing change in quality of a base material provided with the repairing material so as to securely bond the repairing material to a repair target portion. The repair method of the present invention, in order to repair a repair target portion 14 existing in an outer panel 1, includes: a repairing material disposing step of disposing a repairing patch 21 including a resistance heating element 23 and a carbon fiber reinforced resin, and an adhesive 22A including a thermosetting resin before being hardened for bonding the repairing patch 21 on the repair target portion 14; and a heating-hardening step of heating and hardening the thermosetting resin of the adhesive 22A by causing the resistance heating element 23 to generate heat through supply of electricity thereto.

A repair tool for applying a coating patch includes a heating element, a flexible bladder disposed adjacent the heating element, and an inflexible shell disposed about the flexible bladder. The inflexible shell defines a negative space corresponding to a plurality of sides of an aircraft component. A controller is communicatively coupled to the heating element and the bladder, and is configured to control a temperature of the heating element and a pressure of the flexible bladder.

A repair tool for applying a coating patch includes a heating element, a flexible bladder disposed adjacent the heating element, and an inflexible shell disposed about the flexible bladder. The inflexible shell defines a negative space corresponding to a plurality of sides of an aircraft component. A controller is communicatively coupled to the heating element and the bladder, and is configured to control a temperature of the heating element and a pressure of the flexible bladder.