Tendon Sleeve Integration for High-Altitude Balloon Structural Integrity
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Solution Overview
Problem
High-altitude balloons require structural integrity solutions that are efficient and lightweight, as existing methods for securing tendons to the balloon membrane are complex and wasteful, involving separate manufacturing of tendon sleeves and winding of tendons onto spools.
Innovation Solution
The integration of tendon sleeves formed by coupling adjacent gore panels of the balloon membrane, which creates edge flanges to secure tendons in place, eliminating the need for separate tendon sleeves and simplifying the manufacturing process by forming the tendon sleeve, seam joint, and tendon positioning simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tendon sleeves are manufactured and tendons are wound onto spools, then tendon securing is achieved, but device complexity and manufacturing waste increase
Solution Approach 1:
The patent combines the tendon sleeve and the balloon membrane into a single integrated structure. The tendon sleeve is formed from the same material as the balloon membrane and is manufactured as one piece, eliminating the need for separate tendon sleeve components and spools. This merging reduces device complexity while maintaining tendon securing functionality.
Solution Approach 2:
The balloon membrane material serves multiple functions: it forms the balloon structure itself and simultaneously creates the tendon sleeve. The same material and manufacturing process that creates the balloon also produces the tendon securing mechanism, eliminating the need for separate specialized components.
2Reliability
If separate tendon sleeves are manufactured, then tendon securing is achieved, but material waste increases
Solution Approach 1:
The tendon sleeve is merged with the balloon membrane, meaning the same material serves dual purposes. No separate material is required for the tendon sleeve, completely eliminating material waste associated with separate component manufacturing.
Solution Approach 2:
The balloon membrane material performs both structural and tendon-securing functions. This multi-functionality ensures that every portion of the material serves a purpose, eliminating waste from unused or separate components.
3Ease of manufacture
If tendon sleeves are formed by coupling adjacent gore panels with edge flanges, then tendon securing is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The edge flanges are formed as integral parts of the gore panels during the same manufacturing process. This simultaneous formation ensures proper alignment without requiring separate alignment steps, reducing precision requirements while simplifying manufacture.
Solution Approach 2:
The edge flanges are pre-formed as part of the gore panel structure before final assembly. This preliminary formation of the flanges with correct geometry built-in reduces the precision requirements during final assembly compared to adding them separately.
Data Source
AI summary
A system for forming a tendon sleeve on an atmospheric balloon is described herein, the system comprising a coupling assembly including a seam coupling mechanism that forms a seam joint between a first gore panel and a second gore panel, the seam joint is spaced from respective first and second lateral edges of the first and second gore panels to form first and second edge flanges, and an edge coupling mechanism that forms an edge joint between the first and second edge flanges and closes a tendon sleeve, the edge joint spaced from the seam joint, the tendon sleeve includes a tendon sleeve passage between the seam joint and the edge joint and between the first and second edge flanges. The system also includes a tendon positioning mechanism that positions a tendon within the tendon sleeve passage. A tendon sleeve formed by this system is also described herein.