Tendon Placement for High-Altitude Balloon Envelopes
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Solution Overview
Problem
The manufacturing of high-altitude balloon envelopes for communication networks faces challenges in balancing deployment stability with material strain, as existing methods for securing tendons are time-consuming, costly, and prone to damage, and do not adequately prevent longitudinal movement during inflation.
Innovation Solution
A method involving the use of tubing with surface openings and restraining tape, or double-sided adhesive tape, to secure tendons within the balloon envelope, combined with a constant force roller to ensure stability during inflation, and the application of an overhead gantry structure to automate the process and reduce stress concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual techniques (heat sealing or PSA tape) are used to secure tendons, then the balloon envelope can be assembled, but the process becomes extremely time-consuming and has low consistency
Solution Approach 1:
The patent replaces manual mechanical techniques (heat sealing, PSA tape application) with an automated mechanical system consisting of a constant force roller, restraining tape, and groove structure. This automated system consistently applies controlled force to secure tendons, eliminating manual variability and significantly increasing both productivity and placement consistency.
Solution Approach 2:
The patent introduces a constant force roller that maintains a specific, controlled force parameter throughout the tendon securing process. This parameter control ensures consistent tendon placement and secures the tendon between the groove and the restraining tape, transforming a variable manual process into a controlled automated one.
2Reliability
If manual techniques are used to secure tendons, then the balloon envelope can be assembled, but the process is prone to damage and has low consistency
Solution Approach 1:
The patent replaces complex manual operations (heat sealing, PSA tape application, manual positioning) with a simpler automated mechanical system. The constant force roller, groove structure, and restraining tape work together to automatically secure tendons, reducing manufacturing complexity while improving reliability and consistency.
3Adaptability or versatility
If the balloon envelope uses flexible envelope material configured in sections, then the balloon can be deployed, but the material experiences strain during deployment
Solution Approach 1:
The patent divides the balloon envelope into sections (gores) that can be independently configured and assembled. This segmentation allows the envelope to be made from flexible materials while maintaining structural integrity through the tendon and groove attachment system, enabling deployment without excessive material strain.
Solution Approach 2:
The patent introduces a groove structure and restraining tape as intermediary elements between the flexible envelope material and the tendon. These intermediaries distribute and manage the mechanical stress, allowing the flexible material to be used while preventing excessive strain during deployment.
4Productivity
If tendons are secured without automated mechanisms, then the manufacturing process is simpler, but the process is time-consuming and inconsistent
Solution Approach 1:
The patent implements a relatively simple automated mechanical system comprising a constant force roller, groove structure, and restraining tape. This system automatically secures tendons with consistent precision, dramatically improving manufacturing efficiency while introducing only moderate device complexity compared to traditional manual methods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the efficiency and consistency of the manufacturing process, reduces the risk of damage, and maintains tendon stability during inflation, thereby improving the reliability of the balloon envelope's deployment in the stratosphere.
Implementation Method 1
applying a constant force roller to secure the tendon to the gore portion and to secure the tendon to the tubing
Implementation Method 2
the restraining tape is a pressure sensitive adhesive tape
Implementation Method 3
the tubing includes a polyethylene thin film having a first edge along which an adhesive is positioned, and the adhesive is configured to secure the tubing to the gore portion
Data Source
AI summary
Aspects of the disclosure relate to manufacturing balloon envelopes for use in high-altitude mesh networks for packet-data communications. As an example, a gore portion may be placed on a table such that the gore portion overlies a groove within the table. A tendon may be placed on the gore portion and within the groove. A portion of tubing may be placed over the tendon. The tubing may have one or more surface openings. Restraining tape is applied over the one or more surface openings in the tubing. A constant force roller is applied to secure the tendon to the gore portion and to secure the tendon to the tubing. As an alternative or in addition to the surface openings, double-sided restraining tape may be placed between the tendon and the tubing. The tubing and restraining tape may prevent undesired lateral and longitudinal movement of the tendon during deployment.