Abstract: Aspects of the disclosure relate to techniques for manufacturing a balloon envelope. In one example, a first sheet of material for a first gore of the balloon envelope is provided. Lap seal material is arranged at least partially on the first sheet of material. A first heat seal is created between the lap seal material and the first sheet of material. A second sheet of material for a second gore of the balloon envelope is arranged over the first heat seal. A second heat seal is created between the lap seal material and the second sheet of material such that the lap seal material is configured to provide additional structural support to the balloon envelope.

Abstract: Aspects of the disclosure relate to techniques for manufacturing a balloon envelope. In one example, a first sheet of material for a first gore of the balloon envelope is provided. Lap seal material is arranged at least partially on the first sheet of material. A first heat seal is created between the lap seal material and the first sheet of material. A second sheet of material for a second gore of the balloon envelope is arranged over the first heat seal. A second heat seal is created between the lap seal material and the second sheet of material such that the lap seal material is configured to provide additional structural support to the balloon envelope.

Abstract: An assembly for use during manufacture of a balloon envelope that includes a table having first and second levels, an indicator disposed on the first level and a sealing component. The first level is arranged to receive a first sheet portion of material. The indicator is arranged along a lengthwise axis of the table to indicate a position for attaching a tendon to the first sheet portion. The second level is arranged to receive assembled gore portions of the envelope comprising the first sheet portion, the tendon and a second sheet portion of material. The sealing component is configured to move along the table and to apply a heat seal to bond together the first and second sheet portions disposed thereon in order to form at least part of a gore portion of the envelope, such that the tendon is arranged proximate to a centerline of the gore.

Abstract: A method for constructing a balloon assembly includes inserting balloon envelope material which will become an apex of a balloon envelope into a platen opening of a platen; flaring the balloon envelope material outward over the top surface of the platen; positioning a termination plate over the platen opening and within the apex opening; and folding at least some of the balloon envelope that overlies the platen onto the termination plate. The balloon envelope material further includes an apex opening.

Abstract: A balloon apparatus is provided having (1) a cage structure that includes (a) a plurality of vertical tendons, where each of the vertical tendons includes a first end and second end, where the first ends of the vertical tendons are all connected to one another and where the second ends of the vertical tendons are all connected to one another and (b) one or more horizontal tendons, where each horizontal tendon is attached to each of the vertical tendons at a corresponding level of the cage structure and (2) a balloon envelope, where the balloon envelop is arranged inside the cage structure and inflatable within the cage structure.

Abstract: Aspects of the disclosure relate to manufacturing balloon envelopes for use in high-altitude mesh networks for packet-data communications. As an example, a gore portion may be placed on a table such that the gore portion overlies a groove within the table. A tendon may be placed on the gore portion and within the groove. A portion of tubing may be placed over the tendon. The tubing may have one or more surface openings. Restraining tape is applied over the one or more surface openings in the tubing. A constant force roller is applied to secure the tendon to the gore portion and to secure the tendon to the tubing. As an alternative or in addition to the surface openings, double-sided restraining tape may be placed between the tendon and the tubing. The tubing and restraining tape may prevent undesired lateral and longitudinal movement of the tendon during deployment.

Abstract: Aspects of the disclosure relate to fabricating high-altitude balloons having a prebuilt parachute overlying the surface of the balloon envelope to handle catastrophic envelope failures. The balloon envelope is formed from a number of gore panels. Tendons are positioned adjacent to corresponding ones of the gore panels. Each tendon is configured to carry a load caused by pressurized lifting gas within the balloon envelope. The parachute is affixed to at least some of the tendons, and covers at least a portion of the balloon envelope adjacent to the apex of the envelope. The parachute may be sewn onto the tendons. An outer surface of the parachute is covered with a UV-protective material. For instance, an aluminum coating may be vapor-deposited onto the parachute's outer surface. An IR-reflective material may cover an inner surface of the parachute.

Abstract: Aspects of the disclosure relate to fabricating balloon envelopes for high-altitude balloons. One or more segments of reinforcing tape are applied to gore segments of the balloon envelope. The segments are arranged in a ring to circumscribe an upper portion of the balloon envelope, and may be affixed by a pressure sensitive adhesive. Should a catastrophic failure of the balloon envelope occur, the reinforcing tape acts as a ripstop to prevent a tear from extending upward toward the apex of the balloon envelope. Tendons secured to the apex and to a base of the balloon envelope are configured to keep the top film of the envelope in a parachute configuration in the event of a catastrophic failure. The reinforcing tape is positioned above an equator of the balloon envelope, for instance approximately ? of the distance down from the apex to the base of the envelope.

Abstract: Methods and apparatuses are disclosed for altitude control of a high-altitude balloon. A bladder or ballonet is provided within an envelope of a balloon. The bladder is tubular-shaped, is inflatable, and is foldable for insertion into the balloon prior to performing a final seam on the balloon. To stabilize the bladder, the bladder may be attachable to one or more interior surfaces of the envelope with one or more ropes.

Abstract: An inflation diffuser including a non-rigid first section having a passageway for the passage of lift gas passing through a fill port positioned on a balloon envelope, a porous and non-rigid second section attached to the non-rigid first section, wherein the porous and non-rigid second section is comprised of a mesh material, wherein the non-rigid first section is less porous than the porous and non-rigid second section, and wherein the porous and non-rigid second section is not in contact with the balloon envelope at the end of an inflation process to direct lift gas towards the center of, and away from, the balloon envelope.

Abstract: Methods and apparatuses are disclosed for a self-stabilizing ballonet. A bladder or ballonet is provided within an envelope of a balloon. The bladder includes a spheroid body comprising an equator, a top pole, a bottom pole, and an axis crossing through the top pole and the bottom pole. The distance between two poles may be less than the equatorial distance. The bladder is sized and shaped for insertion into an envelope of a balloon and is inflatable to provide altitude control for the balloon.

Abstract: A balloon envelope, having a base layer of ethylene vinyl alcohol (EVOH) and a layer of a second material, that is not EVOH, bonded to at least a portion of an outer-facing surface of the EVOH layer, is provided. The second material may be polyethylene, or a biaxially-oriented polyethylene terephthalate, such as Mylar®. The envelope may also be provided with another layer of the second material bonded to at least a portion of an inner-facing surface of the EVOH layer. The combination of the EVOH layer and the layer of the second material may be less gas-permeable than the EVOH layer alone and the layer of the second material alone.

Abstract: A balloon including a balloon envelope formed with a plurality of adjacent envelope gores sealed together at respective edges of the envelope gores to form an envelope edge seam between each of the adjacent envelope gores, a ballonet positioned within the balloon envelope, the ballonet formed with a plurality of ballonet gores sealed together at their respective edges to form a ballonet edge seam between each of the adjacent ballonet gores, wherein each envelope gore is contiguous with a ballonet gore such that each envelope edge seam between adjacent envelope gores extends into a ballonet edge seam.

Abstract: An assembly for use during manufacture of a balloon envelope that includes a table having first and second levels, an indicator disposed on the first level and a sealing component. The first level is arranged to receive a first sheet portion of material. The indicator is arranged along a lengthwise axis of the table to indicate a position for attaching a tendon to the first sheet portion. The second level is arranged to receive assembled gore portions of the envelope comprising the first sheet portion, the tendon and a second sheet portion of material. The sealing component is configured to move along the table and to apply a heat seal to bond together the first and second sheet portions disposed thereon in order to form at least part of a gore portion of the envelope, such that the tendon is arranged proximate to a centerline of the gore.

Abstract: An apparatus for securing a plurality of tendons to a balloon includes a first and second plate and a cable long enough to extend around a circumference of the first plate. The first plate has a plurality of slots and one more mating ports. Each slot is configured to allow a given tendon from the plurality of tendons to extend through the first plate by inserting a tendon within the slot. The second plate has a surface with one or more mating members attached. Each mating member is configured to connect the first and second plates together by mating with at least one of the one or more mating ports. The cable is configured to pass between the first and second plates so as to couple with each tendon within the plurality of slots in order to secure the tendons to a balloon structure.

Abstract: Methods and apparatuses are disclosed for altitude control of a high-altitude balloon. A bladder or ballonet is provided within an envelope of a balloon. The bladder is tubular-shaped, is inflatable, and is foldable for insertion into the balloon prior to performing a final seam on the balloon. To stabilize the bladder, the bladder may be attachable to one or more interior surfaces of the envelope with one or more ropes.

Abstract: Methods and apparatuses are disclosed for a self-stabilizing ballonet. A bladder or ballonet is provided within an envelope of a balloon. The bladder includes a spheroid body comprising an equator, a top pole, a bottom pole, and an axis crossing through the top pole and the bottom pole. The distance between two poles may be less than the equatorial distance. The bladder is sized and shaped for insertion into an envelope of a balloon and is inflatable to provide altitude control for the balloon.

Abstract: An assembly for use during manufacture of a balloon envelope that includes a table having first and second levels, an indicator disposed on the first level and a sealing component. The first level is arranged to receive a first sheet portion of material. The indicator is arranged along a lengthwise axis of the table to indicate a position for attaching a tendon to the first sheet portion. The second level is arranged to receive assembled gore portions of the envelope comprising the first sheet portion, the tendon and a second sheet portion material. The sealing component is configured to move along the table and to apply a heat seal to bond together the first and second sheet portions disposed thereon in order to form at least part of a gore portion of the envelope, such that the tendon is arranged proximate to a centerline of the gore.

Abstract: A balloon having a balloon envelope formed with a plurality of adjacent envelope sections each formed of a single seamless piece sealed together at their respective edges to form an edge seam between each of the adjacent envelope sections, a tape comprised of fibers applied to a centerline of each of the envelope sections, wherein the envelope sections are constructed such that the edge seam between each of the adjacent envelope sections is longer than the centerline of each of the envelope sections, and wherein a load caused by pressurized lifting gas within the balloon envelope is carried primarily by the fiber tapes on the centerlines of the envelope sections, rather than the edge seams between the adjacent envelope sections.

Abstract: A self-stabilizing bladder or ballonet is provided within an envelope of a balloon. The bladder includes a spheroid body comprising an equator, a top pole, a bottom pole, and an axis crossing through the top pole and the bottom pole. The distance between two poles may be less than the equatorial distance. The bladder is sized and shaped for insertion into an envelope of a balloon and is inflatable to provide altitude control for the balloon.