A Revised Approach to the ULDB Design

The National Aeronautics and Space Administration Balloon Program has experienced problems in the scaling up of the proposed Ultra Long Duration Balloon. Full deployment of the balloon envelope has been the issue for the larger balloons. There are a number of factors that contribute to this phenomenon. Analytical treatments of the deployment issue are currently underway. It has also been acknowledged that the current fabrication approach using foreshortening is costly, labor intensive, and requires significant handling during production thereby increasing the chances of inducing damage to the envelope. Raven Industries has proposed a new design and fabrication approach that should increase the probability of balloon deployment, does not require foreshortening, will reduce the handling, production labor, and reduce the final balloon cost. This paper will present a description of the logic and approach used to develop this innovation. This development consists of a serial set of steps with decision points that build upon the results of the previous steps. The first steps include limited material development and testing. This will be followed by load testing of bi-axial reinforced cylinders to determine the effect of eliminating the foreshortening. This series of tests have the goal of measuring the strain in the material as it is bi-axially loaded in a condition that closely replicated the application in the full-scale balloon. Constant lobe radius pumpkin shaped test structures will be designed and analyzed. This matrix of model tests, in conjunction with the deployment analyses, will help develop a curve that should clearly present the deployment relationship for this kind of design. This will allow the "design space" for this type of balloon to be initially determined. The materials used, analyses, and ground testing results of both cylinders and small pumpkin structures will be presented. Following ground testing, a series of test flights, staged in increments of increasing suspended load and balloon volume, will be conducted. The first small scale test flight has been proposed for early Spring 2004. Results of this test flight of this new design and approach will presented. Two additional domestic test flights from Ft. Sumner, New Mexico, and Palestine, Texas, and one circumglobal test flight from Australia are planned as part of this development. Future plans for both ground testing and test flights will also be presented.