A high-altitude balloon manufacturing apparatus. The apparatus includes one or more extruders and one or more extrusion dies in fluid communication with the extruders. Each extrusion die is shaped to define one or more connector channels and one or more layering channels. The connector channels define extrudate flow paths between the layering channels.

A high-altitude balloon manufacturing apparatus. The apparatus includes one or more extruders and one or more extrusion dies in fluid communication with the extruders. Each extrusion die is shaped to define one or more connector channels and one or more layering channels. The connector channels define extrudate flow paths between the layering channels.

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 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 high altitude balloon. A plurality of layers of coextruded extrudate are formed in a seamless sheet in a shape that defines a balloon envelope. Delaminator layers may be interposed between two or more of the layers of extrudate.

A high altitude balloon. A plurality of layers of coextruded extrudate are formed in a seamless sheet in a shape that defines a balloon envelope. Delaminator layers may be interposed between two or more of the layers of extrudate.

Co-extruded and extruded high-altitude balloons and apparatus and methods for manufacture. A high-altitude balloon has a plurality of layers of coextruded balloon panel extrudate, a first one of the layers extrusion-bonded to a second one of the layers along a first edge, the second one of the layers extrusion-bonded to a third one of the layers along a strip spaced apart from the first edge, extrusion-bonding of successive layers alternating between the first edge and the strip, the first one of the layers and the last one of the layers extrusion-bonded together along a second edge.

Co-extruded and extruded high-altitude balloons and apparatus and methods for manufacture. A high-altitude balloon has a plurality of layers of coextruded balloon panel extrudate, a first one of the layers extrusion-bonded to a second one of the layers along a first edge, the second one of the layers extrusion-bonded to a third one of the layers along a strip spaced apart from the first edge, extrusion-bonding of successive layers alternating between the first edge and the strip, the first one of the layers and the last one of the layers extrusion-bonded together along a second edge.

Described herein are features for a high altitude lighter-than-air (LTA) system and associated methods. The LTA may include a continuous multi-chamber super-pressure balloon (SPB). The SPB may include two, three, four or more chambers. There may be more than one such multi-chamber SPB. A ring may provide structural support between each chamber. A plurality of tendons may extend upwardly and downwardly from the ring around respective upper and lower chambers to bias each of the SPB chambers to a pumpkin shape. The SPB may use a compressor to provide a variable amount of ballast air by pumping in or expelling out ambient air. A zero-pressure balloon (ZPB) may be attached with the continuous multi-chamber SPB. The ZPB may provide lift for the system. The multi-chamber SPB may include lifting gas and ballast air to provide both lifting and descent functions. The SPB may have an internal barrier separating a lift gas compartment from a variable ballast air compartment.

The disclosure provides an HAPR apparatus comprising an inflatable frame configured to generate canopy extension based on surrounding atmospheric pressure. The inflatable frame has a first collapse load limit less than the weight of the canopy at a first pressurized state less than 75 kPa and a second collapse load limit greater than the weight of the canopy at a second pressurized state of greater than 95 kPa. The internal pressure of the inflatable frame is typically about 101 kPa. The HAPR apparatus allows ascension with the canopy hanging under its own weight to reduce ascension time, then generates canopy extension prior to release in essentially a zero velocity, zero dynamic pressure condition.