Coextruded High-Altitude Balloon Envelope Seam
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Solution Overview
Problem
Existing high-altitude balloon manufacturing methods are inefficient due to frequent gas leaks at heat-sealed seams, require large and costly facilities, and are time-consuming, especially when scaling up production, and cannot utilize non-heat sealable materials effectively.
Innovation Solution
The development of a coextrusion process that allows for simultaneous extrusion and bonding of multiple balloon panels from various materials, including non-heat sealable ones, using an apparatus with extrudate dispensers, an extrusion die, and a cooling system, enabling seamless coextruded balloon envelopes with superior strength and reduced manufacturing time and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat-sealed seams are used to join balloon panels, then balloon assembly can be manufactured, but gas leaks occur frequently at the seams
Solution Approach 1:
The invention extracts and eliminates the heat-sealed seams from the balloon structure by using a seamless coextruded balloon envelope. The entire balloon envelope is formed as a single continuous piece through coextrusion, removing the seams that cause gas leaks and replacing them with integral construction.
Solution Approach 2:
The invention uses composite materials by coextruding multiple layers of different materials simultaneously to form the balloon envelope. This allows combination of materials with different properties (such as barrier layers, structural layers, and flexible layers) to create a seamless envelope with superior performance.
2Ease of manufacture
If traditional balloon manufacturing facilities are built, then balloon production can be achieved, but facility costs are very high due to large space requirements
Solution Approach 1:
The invention merges multiple manufacturing operations into a single coextrusion process. The coextrusion apparatus simultaneously forms multiple balloon envelopes in one continuous operation, eliminating the need for separate cutting, assembly, and sealing operations that require large facility spaces.
Solution Approach 2:
The invention implements continuous production through the coextrusion process, where balloon envelopes are formed continuously without interruption. The apparatus can produce multiple balloons in sequence or simultaneously in a continuous manufacturing line, dramatically increasing productivity and reducing facility space requirements.
3Ease of manufacture
If heat sealing process is used to join balloon panels, then balloon assembly can be formed, but manufacturing time is excessive
Solution Approach 1:
The invention performs preliminary action by forming the complete balloon envelope structure in one coextrusion process before any assembly operations are needed. The balloon envelope is pre-formed with all necessary structural features, layers, and configurations during the extrusion process itself, eliminating subsequent assembly time.
Solution Approach 2:
The coextrusion process enables continuous formation of balloon envelopes without interruption. Multiple balloons can be produced in continuous sequence or simultaneously, maintaining constant production flow and eliminating the time losses associated with batch processing, heating, and assembly operations.
4Adaptability or versatility
If non-heat sealable materials are used for balloon panels, then material versatility is improved, but materials cannot be joined together to form balloon
Solution Approach 1:
The invention uses composite materials by coextruding multiple layers of different materials simultaneously. This allows incorporation of non-heat sealable materials such as PET, fiber-reinforced composites, and flexible glass in the balloon envelope structure, combining materials with different properties that cannot be heat sealed together using traditional methods.
Solution Approach 2:
The invention changes the manufacturing parameter from heat sealing to coextrusion bonding. By forming materials in a molten state during coextrusion and bonding them before cooling, the process enables joining of materials that would otherwise be incompatible for heat sealing, expanding material selection flexibility.
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 significantly reduces gas leaks, minimizes facility costs, and enables the production of larger, longer-lasting high-altitude balloons with improved seam strength, using materials like PET and fiber-reinforced composites, while reducing production time and space requirements.
Implementation Method 1
simultaneous coextrusion of a first and second continuous layers of extrudate material from a single extrusion die
Implementation Method 2
cooling the extruded and extrusion bonded layers of extrudate
Data Source
AI summary
A method of fabricating a high-altitude balloon. The method includes coextruding at least two adjacent continuous layers of extrudate, extrusion-bonding the layers of extrudate to one another along an edge of the sheets of extrudate to form a seam, and cooling the extrudate.