Automated balloon assembly machine

• US 10,456,990 B1
• Filed: 08/27/2018
• Issued: 10/29/2019
• Est. Priority Date: 03/24/2016
• Status: Active Grant

• Current Assignee: Aerostar International LLC (CNH Industrial N.V.)
• Original Assignee: Loon, LLC (Alphabet Inc.)
• Inventors: Fourie, Daniel Henry
• Primary Examiner(s): Koch, George R
• Application Number:
  US16/113,539
• Time in Patent Office: 428 Days
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/226 characterised by the cross-section of said heated wire, resistive ribbon, resistive band or resistive strip, e.g. being triangular
• CPC Class Codes: B29C 65/7441 for making welds and cuts of other than simple rectilinear form
• CPC Class Codes: B29C 65/749 Removing scrap deburring welded articles B29C37/04
• CPC Class Codes: B29C 65/7802 Positioning the parts to be joined, e.g. aligning, indexing or centring
• CPC Class Codes: B29C 65/7847 using vacuum to hold at least one of the parts to be joined vacuum work holders in general B25B11/005
• CPC Class Codes: B29C 66/0044 using a separating sheet, e.g. fixed on the joining tool
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/133 Fin-type joints, the parts to be joined being flexible the parts to be joined being rigid B29C66/1312
• CPC Class Codes: B29C 66/2442 in the form of a single arc of circle
• CPC Class Codes: B29C 66/3452 Making complete joints by combining partial joints
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/8122 characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
• CPC Class Codes: B29C 66/81417 being V-shaped
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/836 Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table B29C66/65 takes precedence
• CPC Class Codes: B29C 66/86533 by rails
• CPC Class Codes: B29C 66/9672 : involving special data inputs, e.g. involving barcodes, RFID tags
• CPC Class Codes: B29L 2022/022 : Balloons
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B64B 1/58 : Arrangements or construction of gas-bags; Filling arrangements
• CPC Class Codes: B64F 5/10 : Manufacturing or assembling aircraft, e.g. jigs therefor

Abstract

An assembly for manufacturing a balloon envelope includes a table component and a sealing component. The table component may include a first platform, a second platform, a third platform, and a lateral opening between the first and second platforms. The first and second platforms can receive a first sheet of material that forms a first gore of the balloon envelope and a second sheet of material that forms a second gore of the balloon envelope. At least a portion of the first platform may move relative to the third platform so as to allow for the tendon and the portion of the second sheet attached to the tendon to move toward the third platform. The sealing component may be configured to bond the first sheet to the second sheet in order to join the first and the second gores of the balloon envelope.

Claims

1. A method for assembling a balloon assembly, the method comprising:

providing a first sheet of material, wherein the first sheet of material extends from a second platform of a table component to a third platform of the table component;

positioning a second sheet of material across a first platform, the second platform, and an opening extending between the first and second platforms of the table component so that a first end of the second sheet of material overlies at least a portion of the first sheet of material that overlies the second platform and a second end of the second sheet of material overlies the first platform;

securing a tendon on a portion of the second sheet of material overlying the first platform;

heat sealing the first sheet of material and the second sheet of material together on the second platform;

moving the second end of the second sheet of material from the first platform to the second platform by moving the second end over the tendon; and

moving at least a portion of the first platform to transfer the tendon and the portion of the second sheet of material to the third platform.

2. The method of claim 1, wherein the first platform further comprises a movable extension, and wherein securing the tendon further comprises securing the tendon on a portion of the second sheet of material overlying the movable extension.

3. The method of claim 2, wherein the method further comprises moving the movable extension to increase a size of the opening and so that the tendon is no longer supported by the movable extension.

4. The method of claim 2, wherein the method further comprises moving the movable extension to a first position where a top surface of the moveable extension and a top surface of a remaining portion of the first platform are coplanar to support securing a tendon on a portion of the second sheet of material overlying the first platform.

5. The method of claim 2, further comprising marking a position on the table component for placing the tendon on a portion of the second sheet of material overlying the first platform using an indicator provided on the movable extension.

6. The method of claim 1, further comprising transferring a heat sealed portion to the third platform by moving the second platform so that the first and second sheets of material are no longer supported by the second platform.

7. The method of claim 1, further comprising clamping the first and second sheets of material together while positioned on the second platform.

8. The method of claim 1, wherein the second platform further includes an airflow unit, the airflow unit configured to allow an amount of airflow to temporarily hold portions of the first and second sheets of material overlying the second platform to the second platform.

9. The method of claim 1, wherein after the second end of the second sheet of material is moved to the second platform, providing a third sheet of material extending across the first platform, the second platform and the opening, the third sheet of material overlying a portion of the second sheet of material overlying the second platform.

10. The method of claim 1, wherein heat sealing the first sheet of material and the second sheet of material together on the second platform includes heating sealing the first and second sheets of material together along a length of the second platform.

11. The method of claim 1, wherein the method further comprises cutting excess material from the first and second sheets of material after heat sealing the first sheet of material and the second sheet of material together on the second platform.

12. The method of claim 1, wherein the method further comprises cutting excess material from the first and second sheets of material simultaneously with heat sealing the first sheet of material and the second sheet of material together on the second platform.