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 balloon (10) extending generally axially from an opening (14) at a first end. The balloon comprises an elastomeric film (11) having a first thickness and a plurality of intersecting ribs (12) of a second, greater thickness formed on the film. The ribs are adapted so as to be angled with respect to the axis (13) of the balloon and any axis perpendicular thereto. Such a balloon has increased tear resistance, and can be manufactured with conventional dipping techniques without compromising the integrity of the film. The ribs may comprise a plurality of helices. There is also a former for making such a balloon and a method of using such a former to make such a balloon.

Aspects of the disclosure relate to envelopes for aerial vehicle. The aerial vehicle may include an envelope including a plurality of gores. The aerial vehicle may also include a seal arranged between a pair of the plurality of gores, the seal including six layers of envelope material heat-sealed together.

A polymer film assembly includes a stack of two or more polymer films. At least one of the polymer films includes directionally oriented molecules. The stack includes a first polymer film and a second polymer film layered with the first polymer film. A contracted bond assembly couples the first and second polymer films of the stack. The contracted bond assembly includes heated and contracted configurations. In the heated configuration the contracted bond assembly includes a bond fusion zone and a film interface having directionally disoriented molecules and an interface width between the bond fusion zone and the remainder of the first and second polymer films. In the contracted configuration the film interface is a contracted film interface having a contracted interface width less than the interface width and a contracted thickness greater than one or more of film thicknesses of the first or second polymer films.

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 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.

An assembly for manufacturing a balloon envelope includes a table component and a sealing component. The table component may include a first platform, a second platform, a third platform, and a lateral opening between the first and second platforms. The first and second platforms can receive a first sheet of material that forms a first gore of the balloon envelope and a second sheet of material that forms a second gore of the balloon envelope. At least a portion of the first platform may move relative to the third platform so as to allow for the tendon and the portion of the second sheet attached to the tendon to move toward the third platform. The sealing component may be configured to bond the first sheet to the second sheet in order to join the first and the second gores of the balloon envelope.

The current inventive technology described methods and apparatus for the production of a helium-free balloon having customizable reflective features.

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.