Method of making a balloon catheter includes melt-extruding a thermoplastic polymeric material into a tube, cooling the extruded tube, placing the extruded tube within a capture member and biaxially orienting the polymeric material of the extruded tube while simultaneously tapering at least a section of the extruded tube by radially expanding the extruded tube with pressurized media in the tube lumen and axially expanding the extruded tube with an external load applied on at least one end of the tube as an external heat supply traverses longitudinally from a first end to a second end of the extruded tube in the capture member, wherein an overall axial load on the tubing is varied as at least a section of the tube is heated. The method includes cooling the expanded tube to form a tapered biaxially oriented nonporous thermoplastic polymer tubular member and sealingly securing a balloon proximate a distal end of the tubular member.

Method of making a balloon catheter includes melt-extruding a thermoplastic polymeric material into a tube, cooling the extruded tube, placing the extruded tube within a capture member and biaxially orienting the polymeric material of the extruded tube while simultaneously tapering at least a section of the extruded tube by radially expanding the extruded tube with pressurized media in the tube lumen and axially expanding the extruded tube with an external load applied on at least one end of the tube as an external heat supply traverses longitudinally from a first end to a second end of the extruded tube in the capture member, wherein an overall axial load on the tubing is varied as at least a section of the tube is heated. The method includes cooling the expanded tube to form a tapered biaxially oriented nonporous thermoplastic polymer tubular member and sealingly securing a balloon proximate a distal end of the tubular member.

Aspects of the disclosure provide a fill port apparatus for filling high altitude balloons, such as those used in communications networks, with lighter than air lift gasses. For instance, the fill port apparatus includes a tubular body portion having a passageway extending between a first end and a second end of the tubular body portion. The fill port apparatus also includes an attachment structure arranged at the first end of the tubular body portion. This structure is configured to attach to a top plate of a balloon envelope. The fill port apparatus also includes a plurality of energy directing structures arranged on an interior surface of the tubular body portion. These energy directing structures extend into the passageway from the interior surface and are each configured to contact at least one other of the plurality of energy directing structures when the tubular body portion is welded to itself.

An assembly for use during manufacture of a balloon envelope that includes a table having first and second levels, an indicator disposed on the first level and a sealing component. The first level is arranged to receive a first sheet portion of material. The indicator is arranged along a lengthwise axis of the table to indicate a position for attaching a tendon to the first sheet portion. The second level is arranged to receive assembled gore portions of the envelope comprising the first sheet portion, the tendon and a second sheet portion of material. The sealing component is configured to move along the table and to apply a heat seal to bond together the first and second sheet portions disposed thereon in order to form at least part of a gore portion of the envelope, such that the tendon is arranged proximate to a centerline of the gore.

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.

A method of fabrication of a medical balloon, and a balloon device useful for various medical balloon procedures, such as gastrointestinal, vascular, reproductive system, urinary system and pulmonary applications. At least two layers of a thermoplastic film are sealed at their peripheral edges and heat sealed at one or more locations inside an area enclosed by the sealed edges at predetermined locations, in one implementation of the balloon device. Such configuration enables the balloon to articulate to a desired shape upon inflation, with the desired shape being selected to accommodate a specific medical application.

A method of fabrication of a medical balloon, and a balloon device useful for various medical balloon procedures, such as gastrointestinal, vascular, reproductive system, urinary system and pulmonary applications. At least two layers of a thermoplastic film are sealed at their peripheral edges and heat sealed at one or more locations inside an area enclosed by the sealed edges at predetermined locations, in one implementation of the balloon device. Such configuration enables the balloon to articulate to a desired shape upon inflation, with the desired shape being selected to accommodate a specific medical application.

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.

Aspects of the disclosure relate to systems and techniques for inspecting seals for high altitude balloons. In one example, a system may include a reflective surface, a translucent material on the reflective surface, and a movable light source configured to move along the reflective surface and provide light to the reflective surface. The light is provided such that it is reflected from the reflective surface and through the translucent material in order to backlight a balloon envelope seal for inspection. A method for inspecting a balloon envelope seal may include placing balloon envelope material on a table, forming a seal between portions of the material, moving a light over the seal, shining light onto a reflective portion of the table below the seal to backlight the seal, and inspecting the seal using the backlighting of the seal.

Aspects of the disclosure relate to techniques for manufacturing a balloon envelope including a duct for high altitude balloons. In one example, a first sheet of material may be provided. A premade duct may be arranged at least partially on the first sheet of material. The duct may include a first substance on an internal surface. A second sheet of material may be arranged over at least a portion of the duct. A heat sealing device may be applied to the second sheet of material to heat seal the first sheet of material to the second sheet of material. The heat sealing device may be applied over at least a portion of the duct in order to seal external surfaces of the duct to each of the first and second sheets of material and form a balloon gore. The first substance may keep the duct from being sealed to itself.