Vacuum mold and heating device for processing contoured repair patches

An apparatus for molding a curable patch used in repairing an affected contoured surface, the apparatus comprising in combination:

• a fluid impermeable outer container having a flexible outer wall, the outer container having a resealable opening through which the patch can be introduced into the outer container;
• a flexible, fluid impermeable inner container positioned within the outer container, the inner container containing a moldable granular material, the inner container having a flexible base wall and a flexible molding wall opposite the base wall whereon the patch may be placed;
• an inner port located on the inner container, the inner port having an inner nozzle sealingly protruding through the outer container and being connected to a first vacuum hose of a vacuum source for evacuating the inner container while the molding wall of the inner container is pressed against a contoured surface similar to the affected contoured surface so that the molding wall is drawn against and conforms to the granular material, whereby the granular material is held in a rigid molded form, the molding wall forming a model of the contoured surface so that the patch can be molded to the shape of the model;
• an outer port located on the outer container, the outer port having an outer nozzle connected to a second vacuum hose of the vacuum source for evacuating the outer container so that the outer wall is drawn against the molding wall and patch when the patch is placed on the molding wall to apply pressure to the patch while the patch is curing;
• and
• breather means which locates between the outer container and the base wall of the inner container for providing a space through which fluid can be drawn from between the inner and outer containers when the outer container is evacuated.

An apparatus for molding and curing an uncured composite patch used in repairing an affected contoured surface, the apparatus comprising in combination:

• a fluid impermeable outer container having a flexible outer wall;
• a flexible, fluid impermeable inner container positioned within the outer container, the inner container containing a moldable granular material, the inner container having a flexible base wall and a flexible molding wall opposite the base wall whereon the composite patch may be placed;
• a first vacuum port means attached to the inner container for evacuating the inner container while the molding wall of the inner container is pressed against a contoured surface similar to the affected contoured surface so that the molding wall is drawn against and conforms to the granular material, whereby the granular material is held in a rigid molded form, the molding wall forming a model of the contoured surface so that the patch can be molded to the shape of the model;
• a second vacuum port means attached to the outer container for evacuating the outer container so that the outer wall is drawn against the molding wall and patch when the patch is placed on the molding wall to apply pressure to the patch while the patch is curing;
• a flexible heat cover having a perimeter, the cover being joined to the outer wall of the outer container substantially along the perimeter so that a cavity exists between the outer wall and the heat cover;
• and
• a heating duct connected to the heat cover for introducing a heated fluid within the cavity between the outer wall and the heat cover for curing the molded patch.

An apparatus for molding a curable contoured patch used in repairing an affected contoured surface, the patch having a lower layer and at least one upper layer, the lower layer having greater surface dimensions than the upper layer, creating a perimeter with lesser thickness than a central section of the patch, the apparatus comprising in combination:

• a fluid impermeable first container having a flexible female molding wall, the first container containing a moldable granular material;
• a fluid impermeable second container, the second container having a flexible male molding wall, the second container containing a moldable granular material;
• a first vacuum port means attached to the first container for evacuating the first container while the female molding wall is pressed against an unaffected contoured surface that is equivalent to the affected contoured surface, so that the granular material is molded to conform to the unaffected contoured surface and the female molding wall is drawn against and conforms to the molded granular material, holding the female molding wall in a rigid form;
• a second vacuum port means attached to the second container for evacuating the second container while the male molding wall is pressed against the female molding wall so that the granular material in the second container is molded to the female molding wall and the male molding wall is drawn against and conforms to the molded granular material in the second container, holding the male molding wall in a rigid form so that the patch can be placed and cured on the male molding wall with the lower layer in contact with the male molding wall;
• and
• a fluid impermeable outer container having a flexible outer wall in which the second container can be positioned so that the outer wall is drawn against the male molding wall and patch when the pressure within the outer container is reduced, thereby forcing the patch against the male molding wall so that the patch assumes the shape of the male molding wall while the patch is curing.