A challenge to the highest balloon altitude

Development of a balloon to fly at higher altitudes is one of the most attractive challenges for scientific balloon technologies. After reaching the highest balloon altitude of 53.0 km using the 3.4 μm film in 2002, a thinner balloon film with a thickness of 2.8 μm was developed. A 5000 m³ balloon made with this film was launched successfully in 2004. However, three 60,000 m³ balloons with the same film launched in 2005, 2006, and 2007, failed during ascent. The mechanical properties of the 2.8 μm film were investigated intensively to look for degradation of the ultimate strength and its elongation as compared to the other thicker balloon films. The requirement of the balloon film was also studied using an empirical and a physical model assuming an axis-symmetrical balloon shape and the static pressure. It was found that the film was strong enough. A stress due to the dynamic pressure by the wind shear is considered as the possible reason for the unsuccessful flights. A 80,000 m³ balloon with cap films covering 9 m from the balloon top will be launch in 2011 to test the appropriateness of this reinforcement.     

Evolution of scientific ballooning and its impact on astrophysics research

As we celebrate the centennial year of the discovery of cosmic rays on a manned balloon, it seems appropriate to reflect on the evolution of ballooning and its scientific impact. Balloons have been used for scientific research since they were invented in France more than 200 years ago. Ballooning was revolutionized in 1950 with the introduction of the so-called natural shape balloon with integral load tapes. This basic design has been used with more or less continuously improved materials for scientific balloon flights for more than a half century, including long-duration balloon (LDB) flights around Antarctica for the past two decades. The U.S. National Aeronautics and Space Administration (NASA) is currently developing the next generation super-pressure balloon that would enable extended duration missions above 99.5% of the Earth’s atmosphere at any latitude. The Astro2010 Decadal Survey report supports super-pressure balloon development and the giant step forward it offers with ultra-long-duration balloon (ULDB) flights at constant altitudes for about 100 days.     

Properties of tandem balloons connected by extendable suspension wires

The tandem balloon system has been known as a candidate system for long duration flight balloons. In this paper, the properties of the system are analytically studied in a new way by introducing an extendable suspension wire in the Sky Anchor configuration, which consists of a zero-pressure main balloon suspending a payload and a super-pressure balloon suspended below the payload. It was found that extension of the suspension wire between the payload and the super-pressure balloon can extend the capability of the tandem system; the altitude of the zero-pressure balloon can be changed without any consumables except some energy, and the day–night oscillation of the balloon altitude can be suppressed. This property is useful as the vehicle for long duration flights. It is also pointed out that the method to control the altitude of a balloon using an additional suspended super-pressure balloon can also be applied for super-pressure balloons.     

Progress of super-pressure balloon development: A new “tawara” concept with improved stability

The super-pressure balloon (SPB) has been expected to be a flight vehicle that can provide a long flight duration to science. Since 1997, we have developed the SPB. Now we are at the phase of developing an SPB of a practical size. In 2009, we carried out a test flight of a pumpkin-shaped SPB with a 60,000 m³ volume. The undesirable result of this flight aroused us to resolve the deployment instability of the pumpkin-shaped SPB, which has been known as one of the most challenging issues confronting SPB development. To explore this deployment issue, in 2010, we carried out a series of ground tests. From results of these tests, we found that an SPB design modified from pumpkin, named “tawara”, can be a good candidate to greatly improve the deployment stability of the lobed SPB.     

Development overview of the revised NASA Ultra Long Duration Balloon

The desire for longer duration stratospheric flights at constant float altitudes for heavy payloads has been the focus of the development of the National Aeronautics and Space Administration’s (NASA) Ultra Long Duration Balloon (ULDB) effort. Recent efforts have focused on ground testing and analysis to understand the previously observed issue of balloon deployment. A revised approach to the pumpkin balloon design has been tested through ground testing of model balloons and through two test flights. The design approach does not require foreshortening, and will significantly reduce the balloon handling during manufacture reducing the chances of inducing damage to the envelope. Successful ground testing of model balloons lead to the fabrication and test flight of a ∼176,000 m³ (∼6.2 MCF – Million Cubic Foot) balloon. Pre-flight analytical predictions predicted that the proposed flight balloon design to be stable and should fully deploy. This paper provides an overview of this first test flight of the revised Ultra Long Duration Balloon design which was a short domestic test flight from Ft. Sumner, NM, USA. This balloon fully deployed, but developed a leak under pressurization. After an extensive investigation to the cause of the leak, a second test flight balloon was fabricated. This ∼176,000 m³ (∼6.2 MCF) balloon was flown from Kiruna, Sweden in June of 2006. Flight results for both test flights, including flight performance are presented.     

Mechanical properties of ANTRIX balloon film and fabrication of single cap large volume balloons

The zero pressure plastic balloons used for high altitude studies are generally made from polyethylene material. Tensile properties of the thin film polymer are the key parameters for material selection due to extremely low temperature of −90 °C encountered by the balloons in the tropopause region during the ascent at equatorial latitudes. The physical and structural properties of the material determine the uniformity of the stress distribution over the entire shell. Load stresses from the suspended load propagate via load tapes heat sealed along with the gore seals as per the balloon design. A balance between this heat seal strength and the film strength is a desirable property of the basic resin in terms of the bubble strength, gauge uniformity, and long-term storage properties. In addition, the design of the top shell of the balloon and its stress distribution play an important role since only a fraction of the balloon is deployed during the filling operation and the ascent. In this paper we describe the mechanical properties of the ‘ANTRIX’ film developed by us and the optimized design of single cap balloons, which have been successfully used in our experiments over the past 5 years.     

Launching of a 500,000 cubic meter balloon with the semi-dynamic launching method

Launching a large balloon in a limited launching field is a long standing problem in Japan. The largest balloon ever launched successfully was 200,000 m³ in volume. It was launched in 1973. A larger balloon with a volume of 500,000 m³ was tried later, but it burst during the ascending phase. For launching balloons with a large lift exceeding 500 kg, the conventional static launching method had the most serious problem with possible damage to the polyethylene film of the balloon caused by the holding mechanism. After that, we had developed a new static launching method to launch balloons with a total lift of 1.0 ton. For launching a large balloon with a total lift above 1.5 ton, the new static launching method had a weak point in that if there was an air bubble in the folded part of the balloon, it may puncture the balloon as it is pushed by a spool. To avoid this problem, we developed a semi-dynamic launching method in 1999 using a launcher fixed to the ground leaving a freedom of rotation around the vertical axis. We have launched some balloons using the method and have gradually enriched our experience in using this system.In 2003, we successfully launched a balloon with a volume of 500,000 m³ by using the method. This balloon was made of polyethylene films with a thickness of 20 μm and it is the largest balloon ever launched in Japan.     

Simulating clefts in pumpkin balloons

The geometry of a large axisymmetric balloon with positive differential pressure, such as a sphere, leads to very high film stresses. These stresses can be significantly reduced by using a tendon re-enforced lobed pumpkin-like shape. A number of schemes have been proposed to achieve a cyclically symmetric pumpkin shape, including the constant bulge angle (CBA) design, the constant bulge radius (CBR) design, CBA/CBR hybrids, and NASA’s recent constant stress (CS) design. Utilizing a hybrid CBA/CBR pumpkin design, Flight 555-NT in June 2006 formed an S-cleft and was unable to fully deploy. In order to better understand the S-cleft phenomenon, a series of inflation tests involving four 27-m diameter 200-gore pumpkin balloons were conducted in 2007. One of the test vehicles was a 1/3-scale mockup of the Flight 555-NT balloon. Using an inflation procedure intended to mimic ascent, the 1/3-scale mockup developed an S-cleft feature strikingly similar to the one observed in Flight 555-NT. Our analysis of the 1/3-scale mockup found it to be unstable. We compute asymmetric equilibrium configurations of this balloon, including shapes with an S-cleft feature.     

Prototype design and testing of a Venus long duration,high altitude balloon

This paper describes the design, fabrication and testing of a full scale prototype balloon intended for long duration flight in the upper atmosphere of Venus. The balloon is 5.5 m in diameter and is designed to carry a 45 kg payload at an altitude of 55 km. The balloon material is a 180 g/m² multi-component laminate comprised of the following layers bonded together from outside to inside: aluminized Teflon film, aluminized Mylar film, Vectran fabric and a polyurethane coating. This construction provides the required balloon functional characteristics of low gas permeability, sulfuric acid resistance and high strength for superpressure operation. The design burst superpressure is 39,200 Pa which is predicted to be 3.3 times the worst case value expected during flight at the highest solar irradiance in the mission profile. The prototype is constructed from 16 gores with bi-taped seams employing a sulfuric acid resistant adhesive on the outside. Material coupon tests were performed to evaluate the optical and mechanical characteristics of the laminate. These were followed by full prototype tests for inflation, leakage and sulfuric acid tolerance. The results confirmed the suitability of this balloon design for use at Venus in a long duration mission. The various data are presented and the implications for mission design and operation are discussed.     

Second generation prototype design and testing for a high altitude Venus balloon

This paper describes the development of a second generation prototype balloon intended for flight in the upper atmosphere of Venus. The design of this new prototype incorporates lessons learned from the construction and testing of the first generation prototype, including finite element analyses of the balloon stresses and deformations, measured leak performance after handling and packaging, permeability and optical property measurements on material samples, and sulfuric acid testing. An improved design for the second generation prototype was formulated based on these results, although the spherical shape and 5.5 m diameter size were retained. The resulting balloon has a volume of 87 m³ and is capable of carrying a 45 kg payload at a 55 km altitude at Venus. The design and fabrication of the new prototype is described, along with test data for inflation and leakage performance.