Methods of forming uncured sealant assemblies and using such assemblies for sealing and bonding parts

A method of forming a seal between a first part and a second part using an uncured sealant assembly, the method comprising:

• removing the uncured sealant assembly from a cure-inhibiting temperature,
• wherein the uncured sealant assembly comprises a first protective layer, a second protective layer, and an uncured sealant layer disposed between the first protective layer and the second protective layer,
• wherein the cure-inhibiting temperature is below room temperature and selected to reduce a curing rate of the uncured sealant layer;
• removing the first protective layer from the uncured sealant layer thereby exposing a first sealant surface of the uncured sealant layer;
• contacting the first part with the first sealant surface;
• removing the second protective layer from the uncured sealant layer thereby exposing a second sealant surface of the uncured sealant layer, the second sealant surface being opposite to the first sealant surface;
• and
• contacting the second part with the second sealant surface such that the uncured sealant layer is disposed between the first part and the second part, wherein the uncured sealant layer is cured into the seal,
• further wherein, before contacting the first part with the first sealant surface and before contacting the second part with the second sealant surface, the uncured sealant layer has a thickness, a length, and a width selected based on the shape of a first-part sealed surface of the first part contacting the first sealant surface and also based on the shape of a second-part sealed surface of the second part contacting the second sealant surface, such that no empty space is present between the first part and the second part after contacting the first part with the first sealant surface and without adjusting the first part relative to the second part, and after contacting the second part with the second sealant surface and without adjusting the first part relative to the second part, wherein at least one of the first-part sealed surface and the second-part sealed surface is nonplanar.