Apparatus for Making Extruded and Co-extruded High-Altitude Balloons

Abstract

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.

1 . A high-altitude balloon manufacturing apparatus comprising:
 one or more extruders; and   one or more extrusion dies in fluid communication with the extruders, each extrusion die shaped to define one or more connector channels and one or more layering channels, each connector channel defining one or more extrudate flow paths between two or more of the layering channels.   
     
     
         2 . The apparatus of  claim 1  wherein:
 a first connector channel defines a first extrudate flow path between a first layering channel and a second layering channel; 
 a second connector channel defines a second extrudate flow path between the second layering channel and a third layering channel; and 
 a third connector channel defines a third extrudate flow path between the third layering channel and the first layering channel. 
 
     
     
         3 . The apparatus of  claim 2  wherein the first layering channel is disposed above the second layering channel and the second layering channel is disposed above the third layering channel. 
     
     
         4 . The apparatus of  claim 1  wherein a first layering channel has a first extrudate input and a second layering channel has a second extrudate input. 
     
     
         5 . The apparatus of  claim 4  wherein the first layering channel is disposed adjacent the second layering channel. 
     
     
         6 . The apparatus of  claim 1  wherein a first layering channel has a first extrudate input, each of two second layering channels has a second extrudate input, and the first layering channel is disposed between the second layering channels whereby extrudate exiting from the second layering channels encapsulates extrudate exiting from the first layering channel. 
     
     
         7 . The apparatus of  claim 1  wherein each extrusion die is shaped to define one or more tendon channels adjacent the one or more layering channels. 
     
     
         8 . The apparatus of  claim 1  wherein each extrusion die is shaped to define one or more end encapsulation channels adjacent the one or more layering channels. 
     
     
         9 . The apparatus of  claim 1  and further comprising one or more extrusion die width regulators disposed adjacent the one or more extrusion dies. 
     
     
         10 . The apparatus of  claim 1  wherein the one or more extrusion dies comprises machined hard metal. 
     
     
         11 . The apparatus of  claim 1  wherein the one or more extrusion dies comprise 3D-printed material. 
     
     
         12 . The apparatus of  claim 1  wherein the one or more extrusion dies comprise cast metal. 
     
     
         13 . The apparatus of  claim 1  wherein the one or more extrusion dies comprise blown film dies. 
     
     
         14 . The apparatus of  claim 1  wherein the one or more extrusion dies comprise cast film dies. 
     
     
         15 . The apparatus of  claim 1  wherein at least one of the extrusion dies is shaped to define a layering channel through which lobes extrude as the extrudate flows through the layering channel. 
     
     
         16 . A high-altitude balloon manufacturing apparatus comprising:
 two or more extrudate dispensers, a first one of the extrudate dispensers having an input to receive a first extrudate material and a second one of the extrudate dispensers having an input to receive a second extrudate material;   an extrusion die shaped to define two or more layering channels and one or more connector channels in fluid communication with the extrudate dispensers, the extrusion die having an extrudate outlet in fluid communication with the layering channels;   a support disposed to receive coextruded layers of extrudate from the extrudate outlet; and   a cooler in thermal communication with the extrudate outlet.   
     
     
         17 . The apparatus of  claim 16  wherein the cooler comprises a chill roller. 
     
     
         18 . The apparatus of  claim 16  wherein the cooler comprises a chill roller and a nip roller. 
     
     
         19 . The apparatus of  claim 16  and further comprising a power drive in mechanical communication with coextruded extrudate from the extrudate outlet. 
     
     
         20 . The apparatus of  claim 16  wherein each extrudate dispenser comprises a hopper; an extrusion screw disposed to receive extrudate from the hopper; and a heating element disposed adjacent the extrusion screw. 
     
     
         21 . A high-altitude balloon manufacturing apparatus comprising:
 two or more extrudate dispensers, a first one of the extrudate dispensers having an input to receive a first extrudate material and a second one of the extrudate dispensers having an input to receive a second extrudate material;   an extrusion die shaped to define one or more first layering channels in fluid communication with the first extrudate dispenser and one or more second layering channels in fluid communication with the second extrudate dispenser;   one or more connector channels in fluid communication with the first extrudate dispenser; and   one or more connector channels in fluid communication with the second extrudate dispenser.   
     
     
         22 . The apparatus of  claim 21  wherein at least one of the first layering channels is disposed between two of the second layering channels whereby extrudate exiting from the second layering channels encapsulates extrudate exiting from the first layering channel.