Abstract: A high altitude balloon, including a method and machine for manufacture, uses a perimeter border strip to couple two circular balloon panels with a lap or butt seal. Simultaneous sealing of two perimeter seals, one between the border strip and each of two balloon panels, is provided by supporting stacked balloon panels on a rotatable support and sealing around the full perimeter of the two interposed balloon panels and the border strip. The method and machine for manufacture allow for the mass production of high altitude balloons and minimize necessary material handling. The perimeter border strip can be dispensed and guided relative to the perimeter of the balloon panels for positioning before sealing together, as a bonding device is rotated relative to the balloon envelope.

Abstract: An ultrasonically welded seam formed in thin, semi-crystalline films is provided. In one example embodiment, the seam may include a welded zone flanked by one or more reinforcing perimeter beads, to increase the seam's peel strength and elongation-to-break properties. In one or more embodiments, the seam may be formed by using one or more heat-carrier layers during the ultrasonic sealing of semi-crystalline film layers to generate heat and transfer excess heat across a portion of their surface area and into the semi-crystalline film layers being sealed. The heat-carrier layers enables the film seam to extend wider than the width of the sonotrode and anvil surface areas, creating a reinforcing seam perimeter bead which greatly outperforms prior ultrasonically welded seams of semi-crystalline films.

Abstract: A high altitude balloon comprised of three parts: a body and two end caps. The high altitude balloon includes a substantially cylindrical body formed with a single rectangular sheet of thin membrane material. The end caps can be made of the same thin membrane material, or they may be made from a different material. The end caps may have a substantially hemispherical (dished) shape or flat (disc) shape, though the end caps may have different shapes. Load restraints may be used on the inside or outside of the balloon body to form a plurality of lobes on the balloon body.

Abstract: A high altitude balloon, including a method and machine for manufacture, uses a perimeter border strip to couple two circular balloon panels with a lap or butt seal. Simultaneous sealing of two perimeter seals, one between the border strip and each of two balloon panels, is provided by supporting stacked balloon panels on a rotatable support and sealing around the full perimeter of the two interposed balloon panels and the border strip. The method and machine for manufacture allow for the mass production of high altitude balloons and minimize necessary material handling. The perimeter border strip can be dispensed and guided relative to the perimeter of the balloon panels for positioning before sealing together, as a bonding device is rotated relative to the balloon envelope.