CELEBRATORY BALLOON WITH METALIZATION AND GAS ADMIXTURES

Abstract

A celebratory balloon fabricated from polymeric films have a deposited insularly array of metal which may be further enhanced by polymer encapsulation of the metal. When the balloon is inflated with an admixture of helium and an electronegative gas, the balloon demonstrates to have high breakdown strength across the balloon surface and within the balloon through the inflation gas. The gas mixture further enhances the breakdown strength of the inflation gas by increasing the onset voltage of corona, streamers and spark breakdown. The admixture gas also enhances the breakdown strength of metal-free galloons such as non-metalized balloons, clear balloons, and latex balloons.

Claims

1. A discontinuous metalized celebratory lighter-than-air nylon film balloon, comprising: a) the nylon film balloon is to be inflated with 99.999% pure helium; and b) the nylon film is a surface printed and contains a discontinuous metal layer, a nylon layer, a helium barrier layer, and a heat sealable layer.

2. The celebratory lighter-than-air nylon film balloon of claim 1, wherein the metal layer is a discontinuous aluminum vapor-deposition with a shape pattern of 0.815 mm diameter metal circles densely stacked on a 60-degree hexagonal lattice with a 7.4% separation-to-spacing ratio.

3. The celebratory lighter-than-air nylon film balloon of claim 1, having an inside and an outside wherein the nylon film further comprises from the outside to the inside of the balloon ink/Metal/Nylon/EVOH/Nylon/PE.

4. A discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon, comprising: a) the PET balloon is be inflated with 99.999% pure helium; and b) the PET film is surface printed and contains a discontinuous metal layer, a helium barrier layer, a PET layer, and a heat sealable layer.

5. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon claim of claim 4, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

6. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon of claim 4, having an inside and an outside wherein the PET film further comprises from the outside to the inside the balloon to Ink/Metal/Acrylic/AlOx/PET/PE.

7. An encapsulated, discontinuous metalized PET filmlighter-than-air celebratory balloon, comprising: a) the PET balloon is to be inflated with 99.999% pure Helium; and b) the PET film is surface printed and contains a discontinuous metal layer within an encapsulating layer, a PET layer, and a heat sealable layer.

8. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon claim of claim 7, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

9. The discontinuous metalized, celebratory lighter-than-air PET film balloon claim of claim 7, having an inside and an outside wherein the PET film further comprises from the outside to the inside Ink/PVA/Metal/PET/PE.

10. A discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon, comprising: a) the PET balloon is intended to be inflated with 99.999% pure helium; b) the PET film is surface printed and contains a discontinuous metal layer, a helium barrier layer, a PET layer, and a heat sealable layer; and c) the balloon having an inside and an outside wherein the PET film further comprises from the outside to the inside the balloon to Ink/Metal/PET/PE.

11. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon of claim 10, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

12. A celebratory lighter-than-air, non-latex, clear, free from any metal, balloon fabricated from polymetric films, comprising: a) the polymetric films form a balloon membrane that is surface printed and has a nylon layer, a helium barrier layer and a heat sealable layer; and b) the membrane is to be filled with a lighter-than-air inflation admixture of helium and at least one dielectric gas.

13. The celebratory lighter-than-air balloon of claim 12, having an inside and an outside wherein the nylon film further comprises from outside to inside of the balloon Ink/Nylon/EVOH/Nylon/PE.

14. The celebratory lighter-than-air, balloon of claim 12 wherein the dielectric gas is oxygen.

15. The celebratory lighter-than-air balloon of claim 12, wherein the admixture is 95% helium and 5% oxygen.

16. The celebratory lighter-than-air balloon of claim 12, wherein the balloon having an inside and an outside and is printed with ink thereon and the polymetric films from outside to inside comprise nylon, EVO, a second nylon and polyethylene.

17. A celebratory, non-latex, white pigmented film balloon, free of any metal, comprising: a) the film forms a balloon membrane that is surface printed containing a nylon layer and a heat sealable layer containing a concentration of titanium dioxide particles; and b) the membrane is to be filled with a lighter-than-air inflation admixture of helium and at least one dielectric gas.

18. The celebratory lighter-than-air, balloon of claim 17 wherein the dielectric gas is oxygen.

19. The celebratory lighter-than-air balloon of claim 17, wherein the admixture is 95% helium and 5% oxygen

20. A discontinuous metalized celebratory lighter-than-air nylon film balloon, comprising: a) the nylon film balloon is inflated with admixture of 95% helium and at least one dielectric gas; and b) the nylon film is a surface printed and contains a discontinuous metal layer, a nylon layer, a helium barrier layer, and a heat sealable layer.

21. The celebratory lighter-than-air nylon film balloon of claim 20, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

22. The celebratory lighter-than-air nylon film balloon of claim 20, having an inside and an outside wherein the nylon film further comprises from outside to inside of the balloon Ink/Metal/Nylon/EVOH/a second nylon/PE.

23. The celebratory lighter-than-air, balloon of claim 20 wherein the dielectric gas is oxygen.

24. The celebratory lighter-than-air balloon of claim 20 wherein the admixture is 95% helium and 5% oxygen.

25. A celebratory, discontinuous metalized, lighter than air PET film balloon, comprising: a) the PET balloon is intended to be inflated with admixture of 95% Helium and 5% dielectric gas; and b) the PET film is surface printed and contains a discontinuous metal layer, a PET layer, and a heat sealable layer.

26. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon claim of claim 25, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

27. The discontinuous metalized, celebratory lighter-than-air PET film balloon claim of claim 25, having an inside and an outside wherein the PET film further comprises the outside to the inside Ink/metal/acrylic/ALox/PET/PE.

28. The celebratory lighter-than-air, balloon of claim 25 wherein the dielectric gas is oxygen.

29. A celebratory, encapsulated, discontinuous metalized PET film balloon, comprising: a) the PET balloon is inflated with an admixture of 95% pure Helium and 5% of at least one dielectric gas; and b) the PET film is surface printed and contains a discontinuous metal layer within an encapsulating layer, a PET layer, and a heat sealable layer.

30. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon claim of claim 29, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

31. The discontinuous metalized, celebratory lighter-than-air PET film balloon claim of claim 29, having an inside and an outside wherein the PET film further comprises from the outside to the inside Ink/PVA/Metal/PET/PE.

32. A celebratory discontinuous metalized PET film balloon, comprising: a) the PET balloon is inflated with an admixture of 95% pure Helium and 5% of at least one dielectric gas; and b) the PET film is surface printed and contains a discontinuous metal layer, a PET layer, and a heat sealable layer.

33. The discontinuous metalized, ceramic coated, celebratory lighter-than-air PET film balloon claim of claim 32, wherein the metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage.

34. The discontinuous metalized, celebratory lighter-than-air PET film balloon claim of claim 32, having an inside and an outside wherein the PET film further comprises from the outside to the inside Ink/metal/PET/PE.

35. The discontinuous metalized, celebratory lighter-than-air PET film balloon claim of claim 32 wherein the dielectric gas in oxygen.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0016] FIG. 1 is a prior art general cross sectional view of a balloon membrane for a typical metalized balloon;

[0017] FIG. 2 is a prior art general cross sectional view of a balloon membrane for a typical metalized balloon with the metal layer buried or encapsulated within the film structure;

[0018] FIG. 3 is a prior art general cross sectional view of a balloon membrane for a non-metalized balloon;

[0019] FIG. 4 is a general cross sectional view of a balloon membrane for a discontinuous metalized balloon with the metal layer on top of the film structure;

[0020] FIG. 5 is a general cross sectional view of a balloon membrane for a discontinuous metalized balloon with the discontinuous metal layer encapsulated within the film structure;

[0021] FIG. 6 is a graphic showing of the U.S. Standards and California Standards comparisons for overhead powerlines smallest conductor-to-conductor clearance in inches for a given line voltage;

[0022] FIG. 7 is a graphic showing a division of the graph of FIG. 1 into two regions—Region I not allowed within the U.S. (for nonconductive safe balloons); and Region II represents potentially compliant U.S. overhead powerline designs (for conductive unsafe balloons;

[0023] FIG. 8 is a graphic showing the breakdown voltage for Examples 1-6 of inflated balloons filled with high purity helium gas spanning a simulated overhead powerline;

[0024] FIG. 8a is an enlarged graphic of FIG. 8;

[0025] FIG. 9 is a graphic showing of the breakdown voltage for Examples 7-12 inflated balloons filled with an admix gas of 95% helium and 5% oxygen spanning a simulated overhead powerline; and

[0026] FIG. 10 is a graph showing the admixture effects on the breakdown strength for balloons of the various embodiments.

DETAILED SPECIFICATION

[0027] This invention describes an admixture of a lighter-than-air gas and a dielectric gas, preferably, helium and a dielectric gas, more preferably, helium and an electronegative gas, to increase the overall dielectric strength of the inflation gas retained within the balloon. The lighter-than-air gas may be comprised of one or more lighter-than-air gases. The dielectric gas may be comprised of one or more dielectric gases. Dielectric gases could be but are not limited to: hydrogen, ammonia, carbon monoxide, nitrogen, air, oxygen, chlorine, hydrogen sulfide, carbon dioxide, nitrous oxide, sulfur dioxide, trifluoromethane, tetrafluoromethane (R-14), tetrafluoroethane (R-134a), dichlorodifluoromethane (R-12), hexafluoroethane (R-116), sulfur hexafluoride (146), hexafluoropropane (R-236fa), dichlorotetrafluoroethane (R-114), perfluoropropane (R-218), octafluorocyclobutane (R-C318), and perfluorobutane (R-3-1-10). Some dielectric gases may have negative environmental impacts such as being a greenhouse gas if released or by forming reactive/hazardous chemical species when the admixture is exposed to high voltage. With the introduction of another gas into the lighter-than-air gas, the molecular weight of the dielectric gas becomes important to the buoyancy/lifting capability of the inflated balloon. Dielectric gas molecules heavier than the lighter-than-air gas will have a negative impact on the balloon's lifting capability, i.e. the heavier the dielectric gas molecular weight, the less amount of dielectric gas that can be added to maintain balloon buoyancy. Besides the environmental concerns, the potentially harmful chemical generation, and the potential lifting capability loss, the choice in dielectric gas is also predicated on the dielectric efficiency defined as the rate of dielectric strength improvement given the admixture composition. If the dielectric gas is heavier than the lighter-than-air gas, it is preferable to add the smallest amount of dielectric gas to the lighter-than-air gas to limit the loss of lifting capacity while maintaining the balloon size and still substantially increasing the dielectric strength of the admixture gas without causing additional harm to people and the environment.

[0028] FIG. 4 shows the discontinuous or insular array of a metal layer 401 on top of a balloon membrane film structure 400 and polymer core 401 and a heat sealable layer 403 therebelow.

[0029] A further improvement to the balloon's overall breakdown strength can be made by polymer encapsulation of the discontinuous or insular array of metal by either overcoating the metal layer with a polymer coating or incorporating the metal layer within the polymer film layers within the balloon membrane, as suggested by Sarnstrom. FIG. 5 illustrates an example of a balloon membrane film structure 500 having an insular array of metal 501 on the polymer base core 502 with a heat sealable layer 503 therebelow and encapsulated by a polymer coating 505.

[0030] The polymer coating could be but are not limited to: polyacrylates, polybutylene terephthalate (PBT), polyethylene (PE), polyethylene terephthalate (PET), polyimides, polyurethane (PU), polyvinyl acetate (PVA), polyvinyl alcohol (PVOH), polyvinylidene fluoride (PVDF), and the like. By eliminating the direct metal to gas electrical interactions, the additional dilectric barrier of the encapsulation polymer between the unmetallized gaps of the metal layer can significantly enhance the surface breakdown strength of the balloon film membrane 500. Typical solvent based flexographic inks used for ornamental decorative printing may not provide sufficient dielectric strength to appreciably increase the surface breakdown strength of the balloon. Improvements of polymer encapsulation may only be realized when the disruptive discharge is a flashover at the balloon surface and not an arc-over through the retained gas within the balloon.

[0031] High voltage overhead powerlines tend follow design standards to make the electrical infrastructure inherently safe. A properly designed overhead powerline protects its voltage carrying conductors mainly by physical space separation within an air dielectric. Within the United States, state, local communities, electrical commissions, and electrical municipalities/companies all influence the design of overhead powerlines. However, nearly all governing bodies use design criteria from two established electrical standards: IEEE C2 National Electrical Safety Code or California General Order 95 (CA-GO 95). These standards give guidance on the line-to-line spacing, i.e., conductor-to-conductor clearance, based on the desired powerline voltage level the utilities would like to support. However, the minimum conductor-to-conductor clearance is different between the two standards: In general, the IEEE C2 standard has a continuous voltage-spacing functional relationship while the CA-GO 95 standard has a discrete or step voltage-spacing functional relationship as shown in FIG. 6. For the purpose of this invention, the overhead powerline will be represented by the smallest conductor-to-conductor clearance for a given rated line voltage between the two governing standards More explicitly, the overhead powerline will be characterized and defined as the piece-wise minimum conductor clearance between IEEE C2-1997 Table 235-1 Rule 235B1a, or the 10% reduced California General Order-95 Rule 38 Table 2 Case No. 15 conductor spacing adjusted to conductor clearance by using the NFPA 70 National Electric Code (NEC) Table 310.106(a) minimum conductor size for the rated nominal voltage shown in FIG. 7. The test voltage will also be corrected to the proper rated nominal voltage as defined by ANSI C84.1-2011, table 1, Electric Power Systems Voltage Ratings (60 Hz), Table 1, Voltage Range B for allowable overage voltage.

[0032] If we consider all the potential voltage/conductor separation combinations shown in FIG. 7 that could exist, the characterized overhead powerline divides this space into two regions: Region I and Region II. The region in which a balloon electrically breaks down, i.e., creates a disruptive discharge of a flashover or an arc-over, will define whether the balloon is conductive or non-conductive. According to the Standards, current constructed powerlines can exist for any voltage/conductor separation spacing combination in Region II. Hence, there should not be any existing powerline with the voltage/conductor spacing in Region I. Region I represent higher-stress combinations of voltages and conductor clearances not allowed within the U.S. for overhead powerline design, and Region II represents potentially compliant U.S. overhead powerline designs in accordance with the two established standards. The two regions also define whether the balloon is truly conductive or non-conductive. If the balloon has a disruptive discharge under conditions in Region I, the balloon will not affect any existing compliant powerlines and will be considered a safe, non-conductive balloon. If the balloon has a disruptive discharge in Region II or on the characterized overhead powerline, the balloon has the potential to cause a powerline default and will be considered a conductive balloon. Therefore, for a balloon to be considered safe or “non-conductive” within the powerline, the balloon must reliably not arc-over or flash-over at the designed overhead line spacing in the presence of its designed line voltage. Prior art is ambiguous in defining what constitutes a true non-conductive balloon regarding an overhead powerline. Horii does not define a non-conductive balloon but equates an electroconductive property to a threshold of the film's surface dielectric strength, i.e., a film property. Mount specifically states non-conductive is for the film. While this would be valid for a deflated balloon devoid of inflation gas, it may not be valid for a balloon retaining an inflation gas.

[0033] It is desirable to conduct electrical testing using the voltages, line spacing, and dynamic loading as in a real world overhead powerline would present. Testing on live electrical lines within the United States is prohibited. There are dedicated testing facilities using realistic line voltages, currents, and conductor configurations that are isolated from the normal electrical grid; but these facilities are limited in number and testing is very costly. The typical high voltage testing facility will simulate the utility power system by using high voltage sources such as generator test sets, high voltage test sets, or high potential power sources capable of achieving the desired rated voltage level but cannot achieve output levels of a real powerline. Guidelines and standards exist, such as IEEE Standard 4 or the IEC 60060 equivalent for high voltage testing techniques using such high voltage sources.

[0034] For the purpose of this invention, testing will determine the dielectric breakdown of the balloon and will follow a general procedure of placing a balloon between a pair of test electrodes simulating the electrical conductors of the overhead powerline. The output voltage of a high voltage test set connected to the test electrodes will be increased until a balloon disruptive discharge occurs, such as an arc-over or a flashover. Alternatively, an inflated balloon may be mechanically raised into the pair of energized electrodes until it bridges the electrodes to perform a voltage withstand test. Progressive breakdown or withstand voltage testing is performed on a predefined number of identical samples. It is assumed that the high voltage test setup can deliver sufficient output current to prevent voltage sag even in the presence of partial discharges through the inflation gas. This ensures that the test voltage triggering the disruptive discharge is the same voltage necessary to create a powerline/balloon incident within the normal electrical grid even though the high voltage test setup delivers a much lower short-circuit current.

[0035] The tested examples contained with this invention illustrates the concepts of this invention and is not intended to be limiting in either the balloon film membrane composition and structure, the type and design of the metalized layer, and/or the helium-dielectric gas admixture composition.

Key

[0036] PBT=polybutylene terephthalate
PE=polyethylene
PET=polyethylene terephthalate
PU=polyurethane
PVA=polyvinyl acetate
PVOH=polyvinyl alcohol
PVDF=polyvinylidene fluoride

EXAMPLES

Example 1

[0037] A typical, non-latex, clear polymeric balloon, free of any metal, inflated with 99.999% pure helium. [0038] The balloon membrane is a surfaced printed multilayered polymeric film comprising a nylon layer, a helium barrier layer, and a heat sealable layer. [0039] The film structure consists of Ink/Nylon/EVOH/Nylon/PE.

Example 2

[0040] A typical, non-latex, white pigmented polymeric balloon, free of any metal, inflated with 99.999% pure helium. [0041] The balloon membrane is a surfaced printed multilayered polymeric film comprising a nylon layer and a heat sealable layer containing a concentration of titanium dioxide (Tio2) particles. [0042] The balloon membrane film structure consists of Ink/Nylon/PE with TiO2.

Example 3

[0043] A discontinuous metalized nylon balloon inflated with 99.999% pure helium. [0044] The balloon film membrane is a surface printed multilayered polymeric film comprising a discontinuous metal layer, a nylon layer, a helium barrier layer, and a heat sealable layer. [0045] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0046] The balloon membrane film structure consists of Ink/Metal/Nylon/EVOH/Nylon/PE.

Example 4

[0047] A discontinuous metalized, ceramic coated, PET balloon inflated with 99.999% pure helium. [0048] The balloon membrane film is a surface printed multilayered polymeric film comprising a discontinuous metal layer, a helium barrier layer, a PET layer, and a heat sealable layer. [0049] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0050] The balloon film structure consists of Ink/Metal/Acrylic/AlOx/PET/PE

Example 5

[0051] An encapsulated, discontinuous metalized PET balloon inflated with 99.999% pure helium. [0052] The balloon film membrane is a surface printed multilayered polymeric film comprising an encapsulating layer, a discontinuous a metal layer, a PET layer, and a heat sealable layer. [0053] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0054] The film structure consists of Ink/PVA/Metal/PET/PE.

Example 6

[0055] A discontinuous metalized PET balloon inflated with 99.999% pure helium. [0056] The balloon film membrane is a surface printed multilayered polymeric film comprising a discontinuous metal layer, a PET layer, and a heat sealable layer [0057] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0058] The film structure consists of Ink/Metal/PET/PE

Example 7

[0059] A typical, non-latex, clear polymeric balloon, free of any metal, inflated with an admixture of 95% helium and 5% oxygen. [0060] The balloon film membrane is a surfaced printed multilayered polymeric film comprising a nylon layer, a helium barrier layer, and a heat sealable layer. [0061] The balloon membrane film structure consists of Ink/Nylon/EVOH/Nylon/PE.

Example 8

[0062] A typical, non-latex, white pigmented polymeric balloon, free of any metal, inflated with an admixture of 95% helium and 5% oxygen [0063] The balloon film membrane is a surfaced printed multilayered polymeric film comprising a nylon layer and a heat sealable layer containing a concentration of titanium dioxide particles (TiO2). [0064] The balloon film structure consists of Ink/Nylon/PE with TiO2.

Example 9

[0065] A discontinuous metalized nylon balloon inflated with an admixture of 95% helium and 5% oxygen. [0066] The balloon film membrane is a surface printed polymeric multilayered film comprising a discontinuous metal layer, a nylon layer, a helium barrier layer, and a heat sealable layer. [0067] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0068] The balloon film structure consists of Ink/Metal/Nylon/EVOH/Nylon/PE

Example 10

[0069] A discontinuous metalized, ceramic coated, PET balloon inflated with an admixture of 95% helium and 5% oxygen. [0070] The balloon film membrane is a surface printed multilayered polymeric film comprising a discontinuous metal layer, a helium barrier layer, a PET layer, and a heat sealable layer. [0071] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0072] The balloon film structure consists of Ink/Metal/Acrylic/AlOx/PET/PE

Example 11

[0073] An encapsulated, discontinuous metalized PET balloon inflated with an admixture of 95% helium and 5% oxygen. [0074] The film membrane is a surface printed multilayered film containing an encapsulating layer, a discontinuous metal layer, a PET layer, and a heat sealable layer. [0075] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0076] The film structure consists of Ink/PVA/Metal/PET/PE.

Example 12

[0077] A discontinuous metalized PET balloon inflated with an admixture of 95% helium and 5% oxygen. [0078] The balloon film membrane is a surface printed multilayered polymeric film comprising a discontinuous metal layer, a PET layer, and a heat sealable layer. [0079] The metal layer is an insular array of circular vapor-deposited aluminum arranged in a symmetrical-dense packed pattern with 77-78% metal coverage. [0080] The balloon film structure consists of Ink/Metal/PET/PE.

[0081] Progressive breakdown testing using examples 1 through 6 utilized a pair of utility-grade 14.4 kV 1.5 kVA potential transformers as the high voltage power source. The low voltage (120 volt) inputs of the potential transformers are connected anti-parallel, inductively and resistively ballasted to limit short-circuit current, and driven from a 0-140-volt 20 A variac. The high voltage outputs of the potential transformers are connected in series to form a center-tapped high-voltage transformer with a nominal leg-leg output voltage of 28 kV. The high voltage “center tap” of the pair of potential transformers was also earth grounded. A high-voltage resistor-capacitor network was also connected across the potential transformer outputs. This allowed the charged capacitor in the resistor-capacitor circuit to rapidly discharge hundreds of milliamperes through any newly formed spark channel, creating a distinctive, and very visible, flash that signaled the event. The capacitance also provided a bit of resonant rise (with the ballast inductance), increasing the maximum output voltage to 34-38 kV depending on ballast setting. The potential transformer outputs were also connected to a pair of parallel one inch diameter copper pipes, acting as electrodes and simulating the line conductors of the overhead powerline, and could be adjusted for various spacings in one-inch increments. For balloon voltage breakdown testing, this test setup should behave as a pair of spaced phase-to-phase lines except it will not deliver the huge 60 Hz fault currents seen in an overhead power system.

[0082] Tests using Examples 7 through 12 required a higher voltage source than the tests conducted using examples 1 through 6. The high voltage source was switched to an 80 kV (peak) X-ray transformer repacked into a metal container and fully immersed and vacuum impregnated with transformer oil. The primary of the X-ray transformer was driven from a pair of cascaded 120-volt variable transformers in series with a 6-ohm power resistor bank. This configuration limited the high voltage short-circuit current to about 15 mA. The amperage required for streamer formation in the helium-oxygen admixture was significantly lower than the amperage needed for streamer formation in the 100% helium gas, thus the resistor-capacitor circuit was not needed in this equipment setup. Maximum reliable output voltage for this transformer configuration was limited to 56 kV RMS.

[0083] In all examples, the balloon was inflated with the inflation gas by a Conwin Precision Plus foil-balloon regulator delivering 16-18 inches of water column gauge pressure and inflated to a physical size of approximately 20.5 inches in diameter by 12.75 inches deep. The balloon was slightly wedged between the pair of 1 inch diameter copper pipes. The output voltage of the high voltage transformer was slowly ramped up until there was a visual indication of either an arc-over, or a flash-over, or reached the transformer's maximum output voltage without a disruptive discharge. The output voltage was measured by a true RMS multimeter across a compensated 1,000:1 60 kV voltage divider with the voltage divider connected to one leg of the high voltage transformer.

[0084] The testing of Examples 1 through 6 (shown in FIGS. 8 and 8a) demonstrate when the balloon membrane is classified as “non-conductive”, the balloon can become conductive to overhead powerlines when inflated with relatively pure helium. Test results also show the metal-free balloons of Examples 1 and 2, as well as the discontinuous metalized balloons of Examples 3 through 6, all behaved very similar to each other having arc-overs through the helium inflation gas roughly the same line voltage and conductor clearance values (17 to 21 kV RMS0 at 15.5 to 16.5 inches clearance). Hence a discontinuous metalized polymeric balloon can be configured to mimic the electrical characteristics of a metal-free polymeric balloon when inflated with pure helium.

[0085] When the same balloon membranes used in Examples 1 through 6 are inflated with the admixture gas of 95% helium and 5% oxygen (shown in FIG. 9 as Examples 7 through 12), the balloon voltage breakdown strength significantly increased but in various degrees of improvement. Discontinuous metalized balloons of Examples 9, 10 and 12 demonstrate voltage breakdowns of flashovers across the surface of the balloon indicating the configuration of the metal deposit geometry potential limiting the breakdown improvement. Examples 7 and 8 reached the output voltage limit of the test equipment without a breakdown, this indicating the composition of the inflation gas can significantly contribute to the electrical characteristics of the balloon, particularly when helium is used as the lighter-than-air gas. The encapsulated discontinuous metalized balloon of Example 11 also reached the voltage limit of the test equipment and clearly shows a significant enhancement in breakdown voltage over the patterned metalized balloons of Examples 9, 10 and 12, thus demonstrating the benefits of encapsulating the metal deposits in polymer.

[0086] The balloons in Examples 7 through 12 all remained non-conductive to the distribution class overhead powerlines.

[0087] Additional test were performed to characterize breakdown voltages of various admixtures of helium with oxygen, synthetic air, and dry nitrogen at target concentrations in the range of 0 to 5%. For these tests, a clear balloon with surfaced printed multilayered polymeric balloon membrane comprising a nylon layer and a heat sealable layer was used with electrode clearance of 10, 16 and 20 inches. Results of a 20 inch gap with various admixtures at various concentrations are shown in FIG. 10. Maximum voltage output of the test equipment was limited to approximately 56 k by test equipment limitations. Test results greater than 55 kV are withstand voltages and not actual breakdown voltages. The rated line voltage of a 20 inch conductor clearance is 29.1 kV in accordance with the IEEE C2 specifications, i.e., the characterized overhead powerline. Spark breakdowns were prevented when balloons were inflated with admixtures containing at least 1% oxygen or at least 2% air. This is attributable to the strong electron capturing effect of even small concentrations of oxygen. Removing free electrons increases onset voltages for corona, streamer and leader growth. Admixture using only dry nitrogen are as effective as those containing oxygen (or oxygen as a component of air) since nitrogen is not an electronegative gas.

[0088] Although most U.S. overhead power distribution systems use maximum phase-to-phase voltages of 33 to 35 kV, a few utilities use 38 kV. The corresponding minimum Characterized Overhead Powerline clearance at 38 kV is 23.7 inches. This represents the highest voltage stress (1691 volts/inches) that a 24 inch balloon might encounter within any U.S. power distribution system. Testing has confirmed that nonconductive balloons, when inflated with a helium admixture containing 5% oxygen, should safely withstand phase-to-phase contact with a 38 kV distribution line without suffering catastrophic breakdown. Admixtures containing lower oxygen content or He-air admixtures may be sufficient for regions that use lower distribution system voltages. An emerging IEEE testing standard for non-conducting balloon will likely specify a 5% oxygen 95% helium admixture during qualification testing.

[0089] The above specification, examples and FIGS. are for illustrative purposed only. The true scope of this inventions is described in the following claims.