Abstract: A long life balloon formed from a lamination. The lamination includes a polyester film with a total thickness of 4 ?m to 12 ?m. The polyester film includes a biaxially oriented polyester core layer and at least one amorphous copolyester skin layer. The lamination also includes a sealant layer and a gas barrier layer on an opposite side of the polyester film from the sealant layer. The oxygen transmission rate of the balloon is less than 0.1 cc/100 sqin/day, a bonding strength of the gas barrier layer to the surface of the polyester film is more than 300 g/in at dry conditions, a sealing strength of the balloon is more than 3.5 kg/in, and a floating time of the balloon is more than 20 days.

Abstract: A long life balloon formed from a lamination. The lamination includes a polyester film with a total thickness of 4 ?m to 12 ?m. The polyester film includes a biaxially oriented polyester core layer and at least one amorphous copolyester skin layer. The lamination also includes a sealant layer and a gas barrier layer on an opposite side of the polyester film from the sealant layer. The oxygen transmission rate of the balloon is less than 0.1 cc/100 sqin/day, a bonding strength of the gas barrier layer to the surface of the polyester film is more than 300 g/in at dry conditions, a sealing strength of the balloon is more than 3.5 kg/in, and a floating time of the balloon is more than 20 days.

Abstract: A long life balloon formed from a lamination. The lamination includes a polyester film with a total thickness of 4 ?m to 12 ?m. The polyester film includes a biaxially oriented polyester core layer and at least one amorphous copolyester skin layer. The lamination also includes a sealant layer and a gas barrier layer on an opposite side of the polyester film from the sealant layer. The oxygen transmission rate of the balloon is less than 0.1 cc/100 sqin/day, a bonding strength of the gas barrier layer to the surface of the polyester film is more than 300 g/in at dry conditions, a sealing strength of the balloon is more than 3.5 kg/in, and a floating time of the balloon is more than 20 days.

Abstract: A method of constructing an aerostat involves using a self-mating adhesive system to bind a first barrier film and a second barrier film together. The adhesive precursors of the self-mating adhesive system are applied to the first and second barrier films at the desired point of bonding between the films. Following the application of the adhesive precursors, the barrier films are pressed together to bring the adhesive precursors into contact with each other. A self-mating adhesive layer, which binds the first and second barrier films together, is formed as a result of the reaction between the adhesive precursors. Thereafter the aerostat is die cut out of the web film. The method of the present invention results in aerostats with a bond line at the edge of the desired shape. These aerostats have a reduced weight compared to aerostats made using conventional practices employing a heat sealing layer.

Abstract: A long life balloon formed from a lamination. The lamination includes a polyester film with a total thickness of 4 ?m to 12 ?m. The polyester film includes a biaxially oriented polyester core layer and at least one amorphous copolyester skin layer. The lamination also includes a sealant layer and a gas barrier layer on an opposite side of the polyester film from the sealant layer. The oxygen transmission rate of the balloon is less than 0.1 cc/100 sqin/day, a bonding strength of the gas barrier layer to the surface of the polyester film is more than 300 g/in at dry conditions, a sealing strength of the balloon is more than 3.5 kg/in, and a floating time of the balloon is more than 20 days.

Abstract: A process for fabricating a high barrier lamination suitable for the construction of lighter than air materials including providing a thin, two layer thermoplastic film consisting of an amorphous copolyester skin and a high crystalline polyester core; plasma treating the high crystalline polyester core layer to a surface energy of about 50 to about 68 dyne; depositing a metal barrier layer to an optical density of about 2.2 to about 3.2; and extrusion coating a linear low density polyethylene sealant layer on the amorphous copolyester skin layer.