Contiguous Gore Balloon Envelope and Ballonet Manufacturing
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Solution Overview
Problem
The existing manufacturing process for high-altitude balloons requires separate construction and handling of balloon envelopes and ballonets, leading to increased production time, space requirements, and potential damage, as well as inefficiencies in material usage and automation.
Innovation Solution
The process of forming a balloon envelope and ballonet using contiguous gores, where envelope gores are sealed together in a continuous motion to form both the envelope and ballonet simultaneously, allowing for automated heat sealing and reduced material handling, with the option to use lighter or thinner materials for the ballonet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate construction and handling of balloon envelopes and ballonets is used, then structural integrity can be maintained, but production time and space requirements increase
Solution Approach 1:
The patent combines the construction of the balloon envelope and ballonet into a single integrated process. The envelope gores and ballonet gores are formed simultaneously from contiguous material, eliminating the need for separate construction and handling of these components. This merging reduces production time and space requirements while maintaining structural integrity through continuous sealing operations.
Solution Approach 2:
The patent implements preliminary action by positioning the load ring over the constructed envelope-ballonet structure before inversion. The contiguous gores are sealed and configured in their final positions during the formation process, with the ballonet gores positioned to receive the load ring beforehand. This preliminary configuration eliminates subsequent handling steps and reduces production time.
2Extent of automation
If separate construction of envelope and ballonet is performed, then material selection flexibility is maintained, but material handling and automation efficiency decrease
Solution Approach 1:
The patent merges the envelope and ballonet construction into a single automated process. Contiguous gores are sealed together in one continuous operation, enabling automated heat sealing without manual intervention for transferring or positioning separate components. This integration significantly improves automation efficiency while reducing material handling complexity.
Solution Approach 2:
The patent implements continuity of useful action through continuous sealing operations that form both envelope and ballonet structures in an unbroken sequence. The contiguous gores are sealed edge-to-edge without interruption, eliminating idle time and manual handling steps between separate construction operations, thereby maximizing automation efficiency.
3Productivity
If contiguous gores are sealed in continuous motion, then production efficiency increases, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements feedback control in the continuous sealing process through sensor systems that monitor seal quality, temperature, and position in real-time. The sealing apparatus adjusts parameters dynamically based on feedback from the sealing operation, ensuring consistent precision throughout continuous production. This feedback mechanism maintains high manufacturing precision while enabling continuous operation and high productivity.
Solution Approach 2:
The patent replaces manual mechanical sealing with automated heat sealing systems that provide precise, consistent sealing through controlled thermal energy. The automated system uses programmed motion and temperature control to achieve uniform seal quality across all contiguous gores, maintaining high precision while enabling continuous high-volume production.
4Weight of moving object
If ballonet is made from lighter or thinner material, then weight is reduced, but structural strength may be compromised
Solution Approach 1:
The patent applies local quality by using lighter or thinner material specifically for the ballonet portion while maintaining appropriate material properties for the envelope. The ballonet gores are constructed with optimized material thickness and density suited for their specific function, reducing overall weight while maintaining sufficient strength through the integrated construction and load distribution provided by the contiguous gore design.
Solution Approach 2:
The patent employs composite materials by combining different material properties in the envelope and ballonet structures. The envelope uses material optimized for external strength and environmental resistance, while the ballonet uses lighter material optimized for internal pressure containment. The integrated construction of contiguous gores ensures compatible thermal and mechanical properties at the interface, maintaining overall structural strength while reducing weight.
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 method reduces production time and space requirements, increases automation and efficiency, and allows for the simultaneous construction of the balloon envelope and ballonet from a single material roll, enhancing manufacturing volume and reducing costs while maintaining structural integrity and stability.
Implementation Method 1
allowing for automated heat sealing
Data Source
AI summary
A balloon including a balloon envelope formed with a plurality of adjacent envelope gores sealed together at respective edges of the envelope gores to form an envelope edge seam between each of the adjacent envelope gores, a ballonet positioned within the balloon envelope, the ballonet formed with a plurality of ballonet gores sealed together at their respective edges to form a ballonet edge seam between each of the adjacent ballonet gores, wherein each envelope gore is contiguous with a ballonet gore such that each envelope edge seam between adjacent envelope gores extends into a ballonet edge seam.