GB2381472A

GB2381472A - Balloons and manufacturing systems and method for producing balloons

Info

Publication number: GB2381472A
Application number: GB0126460A
Authority: GB
Inventors: Graham J Evans
Original assignee: H H PLASTICS Ltd
Current assignee: H H PLASTICS Ltd
Priority date: 2001-11-03
Filing date: 2001-11-03
Publication date: 2003-05-07
Anticipated expiration: 2021-11-03
Also published as: GB2381472B; GB0126460D0

Abstract

A substantially continuous manufacturing system for producing balloons having self-sealing valves. The balloons produced by the manufacturing system include a first balloon layer 5c and a second balloon layer 7c wherein portions of the first and second balloon layers 5c, 7c are bonded together at their edges to form a sealed balloon envelope, and further including a self-sealing valve located between said first and second balloon layers 5c, 7c, said valve having a first valve layer 2 and a second valve layer (1, fig 3) wherein portions of the first and second valve layers 2 are bonded together to form a channel 18 having an inlet 17 and an outlet 19, and further including a first hole 20 formed in the first valve layer 2 in communication with the channel inlet 17 and a second hole 21 formed in the first balloon layer 5c providing access to the first hole 20, wherein the first balloon layer 5c and the first valve layer 2 are sealed to one another to prevent gas escaping from the balloon between those layers. The valve layers 2 may form a webbing 24 extending between the channel 18 and the peripheral portions of the balloon layers 5c, 7c. Also disclosed is a valve for use in a balloon.

Description

Balloons and Manufacturing System and Method for Producing Balloons The present invention relates to balloons and a manufacturing system and a method for producing balloons, and in particular but not exclusively metallised balloons.

Metallised balloons are well known in the art. They are often bought for celebrations such as birthdays and weddings and are frequently filled with a lighter than air gas such as helium to enable them to float.

One type of metallised balloon has a self-sealing plastic valve such as described in US 4,917, 646. The valve is made from two strips of sheet plastic material, one slightly longer than the other, which are sealed together to form a channel having an inlet and outlet. The valve also includes a barrier of heat resistant ink at the valve inlet to prevent the inlet from being sealed during the process of forming the peripheral balloon seal.

Typically, a balloon valve is produced separately from a balloon body and inserted between the metallised sheets that form the balloon envelope during the balloon manufacturing process. This is an inefficient process.

Accordingly the present invention seeks to provide an improved balloon and an improved balloon manufacturing process. In particular the present invention seeks to provide a more integrated manufacturing process.

According to one aspect of the current invention there is provided a balloon including a first balloon layer and a second balloon layer wherein portions of the first and second balloon layers are bonded together at their edges to form a sealed balloon envelope, and further

including a self-sealing valve located between said first and second balloon layers, said valve c t : l having a first valve layer and a second valve layer wherein portions of the first and second valve layers are bonded together to form a channel having an inlet and an outlet, and further including a first hole formed in the first valve layer in communication with the channel inlet and a second hole formed in the first balloon layer providing access to the first hole, wherein the first balloon layer and the first valve layer are sealed to one another to prevent gas

escaping from the balloon between those layers. z : l

The arrangement of the first and second holes and the channel inlet is such that when an inflation device is inserted through the first and second holes, gas can be injected from the inflation device through the channel to inflate the balloon.

Advantageously peripheral portions of said valve layers are sealed between peripheral portions of said balloon layers- Advantageously the balloon can include webbing between the channel and peripheral portions of said balloon layers. Preferably portions of at least one of the first and second valve layers form the webbing between the channel and peripheral portions of said balloon layers. In one embodiment the webbing forms pockets between the channel and portions of the balloon envelope.

Advantageously the first valve layer is bonded to the first balloon layer, and the second valve layer is bonded to the second balloon layer at the edges of the layers.

Advantageously the first and second holes are substantially concentric.

Advantageously the balloon has a main body portion and a neck portion, said neck portion including a mouth that is contiguous with the main body portion and wherein the channel inlet is contiguous with the mouth and the channel is located substantially within the main body portion.

Advantageously the first balloon layer and the first valve layer can be sealed to one another around the circumference of the first and second holes.

According to another aspect of the present invention there is provided a manufacturing system for producing balloons having self-sealing valves, the manufacturing system including: a feeding mechanism for feeding a plurality of plastics web materials including first and second valve layers and first and second balloon layers; means for bonding together said first and second valve layers to form a self-sealing valve having an inlet, a channel and an outlet; means for forming a first hole in the first valve layer and means for forming a second hole in the first balloon layer; means for bonding together the first balloon layer and the first valve layer to prevent gas escaping from the balloon between those layers; and

means for bonding said first and second balloon layers together to form a peripheral seal, with the first and second valve layers located between the first and second balloon layers.

Advantageously the first and second holes can be formed substantially concentrically.

Advantageously the first and second holes can be formed in a single operation.

Advantageously the means for bonding together the first balloon layer and the first valve layer can be incorporated with the hole forming means, such that a single operation of the combined means forms the first and second holes and bonds together the first balloon layer and the first valve layer.

Advantageously a separating device can be included to separate portions of the superimposed valve layers which have not been bonded together. Preferably the separating device folds a portion of the second valve layer through an angle of approximately 90 degrees. In one embodiment the folding device folds a portion of the second valve layer through an angle of approximately 90 degrees exposing a portion of the first valve layer to the hole forming means. The hole forming means is then able to form a hole through the first valve layer.

Advantageously the means for bonding said first and second balloon layers together can bond portions of at least one of the valve layers to at least one of the balloon layers.

Advantageously portions of at least one of the valve layers form webbing between the selfsealing valve and the balloon layers.

Advantageously at least one of the valve layers and at least one of the balloon layers is rotatably mounted on a shaft.

Advantageously at least one of the bonding means is a heat sealing means.

Advantageously the means for bonding together the first balloon layer and the first valve layer can form an airtight seal around the circumference of the first and second holes.

According to another aspect of the present invention there is provided a method of

manufacturing balloons having self-sealing valves, the method including the steps : 0 t, superimposing a first valve layer onto a second valve layer ; bonding together portions of the c

first and second valve layers to form a channel, said channel having an inlet and an outlet; superimposing the first and second valve layers onto a portion of a first balloon layer ; forming a first hole through the first valve layer; forming a second hole through the first balloon layer; bonding portions of the first valve layer to portions of the first balloon layer to form an airtight seal to prevent gas escaping from the balloon between those layers; superimposing a second balloon layer onto the first balloon layer locating the first and second valve layers there between; and bonding portions of the first and second balloon layers together to form an airtight seal around the periphery of the balloon.

Advantageously the method can include the additional step of separating portions of the first

and second valve layers not bonded together. z : l Advantageously the width of the balloon layers is greater than the width of the valve layers.

Advantageously the ratio of the width of the balloon layers to the width of the valve layers is in the range of 1: 2 to 1: 5, and is preferably approximately 1: 3.

Advantageously the first and second holes can be formed by a single operation.

Advantageously the step of bonding portions of the first balloon layer to portions of the first valve layer can be performed substantially simultaneously with the hole forming operation.

Advantageously the method is performed by a substantially continuous manufacturing process.

Advantageously the step of bonding portions of the first valve layer to portions of the first balloon layer can form an airtight seal around the circumference of the first and second holes.

According to another aspect of the present invention there is provided a valve for a balloon t : l including a first valve layer and a second valve layer wherein portions of the first and second valve layers are bonded together to form a channel having an outlet and an inlet, and wherein a hole is formed in the first valve layer close to and substantially in line with the channel.

Advantageously portions of at least one of the first and second valve layers form webbing on at least one side of the channel.

Advantageously the webbing is arranged for attachment to at least one balloon layer.

In one embodiment the channel is substantially tubular. In another embodiment the channel has at least one tapering portion wherein the channel inlet is larger than the channel outlet.

An embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings, wherein : Figure 1 is a schematic diagram showing steps in a balloon valve manufacturing process ; Figure 2a is a plan view showing bonding upper and lower valve layers together ; Figure 2b is a cross section showing bonding upper and lower valve layers together ; Figure 3a is a plan view showing bonding a lower valve layer to a lower balloon layer and stamping a hole through both layers ; Figure 3b is a cross section showing bonding a lower valve layer to a lower balloon layer and stamping a hole through both layers ; C) c Figure 3c is a cross section showing the edge alignment of a lower valve layer, an w upper valve layer and a lower balloon layer ; Figure 4a is a plan view showing bonding balloon and valve layers together defining the shape of the balloon ; Figure 4b is a cross section showing bonding balloon and valve layers together defining the shape of a balloon ; and Figure 5 is a partially exploded perspective view showing a balloon including a selfsealing valve made in accordance with the present invention.

An example of a balloon manufactured in accordance with the present manufacturing system is shown in Figure 5. Figure 5 shows a balloon partially exploded to expose some of the internal features.

The balloon includes two superimposed balloon layers 5c and 7c of a metallised plastics material such as PA BIO MET. 12/LIN. PE 15 GR, which are bonded to one another at their edges 23 to form a sealed envelope. The shape of the sealed envelope effectively defines the shape of the balloon. The balloon has a main body 28 and a neck 27.

The balloon further includes a self-sealing valve including two layers 1,2 of a plastics material such as LDPE. The valve is defined by bonds 16 between layers 1,2 which further define a channel 18, a valve inlet 17 and a valve outlet 19. Typically the valve inlet 17 is larger than the valve outlet 19 and the channel 18 is tapered or includes a tapered portion.

The second valve layer 2 has a first through hole 20 in the vicinity of the valve inlet 17.

The neck 27 includes superimposed balloon layers 5c, 7c with valve layers 1,2 located there between, the first hole 20 formed through valve layer 2, a second hole 21 formed through balloon layer 5c and arranged in communication with first hole 20, and a bond 23c, which

bonds the balloon layers 5c, 7c together, bonds the valve layers 1, 2 together and bonds c t : l balloon layers 5c, 7c to the valve layers 2, 1 at the edges of the neck 27. A second bond 23d is included at one end of the neck 27. The mouth 26 of the neck 27 is located at the other end of the neck 27. A third bond between the second valve layer 2 and the first balloon layer 5c is also included in the neck 27 providing an airtight seal around the circumference of the holes 20, 21.

The valve is sandwiched between the balloon layers 5c, 7c and is typically located such that portions of the valve layers 1,2 are positioned within the balloon neck 27 and portions of the valve layers 1,2 are positioned within the main body 28 of the balloon. The valve inlet 17 is in communication with the balloon neck 27 and is typically located at the mouth 26 of the balloon neck 27 with the channel 18 positioned within the main body 28 of the balloon substantially in line with the balloon neck 27. Preferably, the bond 23 defining the balloon envelope crosses bonds 16 in the valve layers 1,2 in the vicinity of the mouth 26 of the balloon neck 27 and is generally indicated by reference 23a. The bond 23a ensures that

inflation gas is directed through the valve inlet 17 and along the channel 18 into the balloon z body by providing an airtight seal between the valve and the balloon neck 27.

The first hole 20 is located substantially centrally within the neck 27 and substantially in line with the channel 18.

The balloon also has webbing 24 on both sides of the channel 18 integrally formed by the

upper and lower valve layers 1, 2. The webbing 24 is attached to the metallised layers 5c, z : l 7c generally indicated by bond 23b.

The second hole 21 is arranged such that the holes 20, 21 are in communication with each other. Preferably the holes 20,21 are substantially concentric. Since the holes 20,21 are in communication with each other when an inflation device is inserted into the balloon through the holes 20,21 gas is directed along the neck 27 of the balloon to the valve inlet 17. The

gas then passes along the channel 18 and exits the valve through the valve outlet 19 into the tz 9 main body 28 of the balloon. The first balloon layer 5c and the second valve layer 2 are sealed to one another around the circumference of the holes 20, 21, to prevent gas escaping from the balloon between the layers 2, 5c when the balloon is inflated.

Figure 1 shows a system for manufacturing balloons, including an upper valve layer 1, having an underside 1 b, and a lower valve layer 2. Valve layers 1,2 are supplied on a roll 3 which thus carries a double layer of material on a single roll. The valve layers 1,2 are made from LDPE and are supplied in 2000 m lengths, having a width of 20 cm and a thickness of 25 am. The roll 3 is rotatably mounted and allows the layer materials 1, 2 to be wound off the roll 3 by a sealing belt and pressure roller via a series of rollers generally indicated as feature 25.

An upper balloon layer 7 is supplied on a roll 8 and a lower balloon layer 5 is supplied on a roll 6. The upper and lower balloon layers 7,5 are identical and are made from PA BIO MET. 12/LIN. PE 15 GR and are supplied in 2000 m lengths, having a width of 60 cm and a weight of 32 g/m2. The rolls 6 and 8 are rotatably mounted and allow the balloon layers 5, 7 to be pulled off the rolls 6,8 by a series of rollers 25.

The ratio of the width of the valve layers 1, 2 to the width of the balloon layers 5, 7 is preferably in the range 1 : 2 to 1 : 5 and is typically approximately 1 : 3.

A heat sealing device 4 is positioned above the upper valve layer I and the lower valve layer 2 and is arranged to seal portions of the valve layers 1,2 together.

A separating device 12 is arranged to fold a portion of the upper valve layer 1 away from the lower valve layer 2 exposing a portion of the lower valve layer 2 and a portion of the underside 1 b of the upper valve layer 1. The edge la refers to the edge (thickness) of the upper valve layer 1.

The upper valve layer 1 is folded through approximately 90 degrees allowing access to the lower valve layer 2 by a heat sealing stamp 9. The heat sealing stamp 9, which includes a punch 11 and a heat sealing element 10, is positioned above the lower valve layer 2 and the lower balloon layer 5 and is arranged to stamp holes through the lower valve layer 2 and the lower balloon layer 5 and to bond the lower valve layer 2 to the lower balloon layer 5 around the circumference of the holes.

A balloon shaping device 22 comprising a sealing head is positioned above the upper valve layer 1, the lower valve layer 2, the lower balloon layer 5 and the upper balloon layer 7 and bonds portions of the balloon layers 5,7 together to form sealed envelope locating the valve layers 1, 2 there between. The balloon shaping device 22 can also bond the valve layers 1, 2 to the balloon layers 7,5. Preferably, excess material is removed by additional trimming equipment. Optionally, the balloon shaping device 22 can be arranged to remove excess material in a single sealing and trimming operation.

The operation of the balloon manufacturing system will now be explained with reference to ZD Figures 1 to 5, in which like reference numerals refer to like features.

Operation of the manufacturing system is substantially continuous and integrates the production of self-sealing valves for metallised balloons and the production of metallised balloon bodies. The resultant product is a metallised balloon incorporating a self-sealing valve.

The upper and lower valve layers 1, 2 are pulled from a common roller 3 by a sealing belt and pressure roller via rollers 25 and are fed to heat sealing device 4 at substantially the same speed. The direction of the movement of materials is generally indicated by the arrow A. The upper and lower valve layers 1. 2 are made from the same plastics sheet material and

are of substantially equal dimensions. The heat sealing device 4 applies pressure and heat to the upper and lower valve layers 1,2, forming two bonds 16 between the layers 1,2 (see Figures 2a and 2b). The bonds 16 between the upper and lower layers 1,2 define the edges of the valve.

The valve comprises an inlet 17, a tapering tubular channel 18 and an outlet 19. The bonds 16 are formed such that the outlet 19 is close to one edge of the upper and lower valve layers 1,2 and the longitudinal axis of the valve is substantially perpendicular to the direction of movement A of the materials.

A lower balloon layer 5 is fed below the upper and lower valve layers 1,2 by a sealing belt and pressure roller via rollers 25. The balloon layer 5 is a metallised sheet material such as PA BIO MET. 12//LIN. PE 15 GR and is approximately 60 cm wide. The upper and lower valve layers 1,2 are made from LDPE and are approximately 20 cm wide.

The lower balloon layer 5 is fed beneath the upper and lower valve layers 1,2 such that the upper and lower valve layers 1,2 are superimposed onto the balloon layer 5, and the lower valve layer 2 is sandwiched between the upper valve layer 1 and the lower balloon layer 5 (see Figures 3a and 3b). Furthermore, the layers 1, 2,5 are aligned as shown in Figure 3c such that first longitudinal edges la, 2a of each of the valve layers 1,2 are superimposed over a first longitudinal edge 5a of the lower balloon layer 5 (Figure 3c is a cross section of Figure 3a before the upper valve layer 1 is folded back).

Alternatively, the upper and lower valve layers 1, 2 can be superimposed onto the balloon layer 5 such that the first longitudinal edges 1 a, 2a, 5a of the layers 1,2, 5 are substantially parallel and the edges 1 a, 2a of the upper and lower valve layers 1, 2 are offset from the edge 5a of the lower balloon layer 5 by a short distance, for example 5 cm, such that the balloon layer 5 over-laps the upper and lower valve layers 1,2.

The upper and lower valve layers 1, 2 and the lower balloon layer 5 are then fed towards the heat sealing stamp 9. Before the channel 18 reaches the heat sealing stamp 9, portions of the

upper valve layer 1 and lower valve layer 2 are separated. This is achieved by folding back z : l part of the upper valve layer 1 through approximately 90 degrees by a layer separating device 12. The separating device 12 is an arrangement of guide plates and rollers. To

separate the upper valve layer 1 from the lower valve layer 2, a part of the upper valve layer 1 is folded about a longitudinal axis which is substantially parallel to edge la and is positioned at approximately half the width of the layer 1, i. e. approximately 10 cm from edge la (see Figures 3a and 3b). The portion of the layer 1 raised through 90 degrees does not have bonds 16.

Separating a portion of the upper valve layer 1 by folding through approximately 90 degrees exposes the layer's underside lb and a portion of the lower valve layer 2 which is superimposed on the balloon layer 5.

When the channel 18 is aligned with the heat sealing stamp 9, the heat sealing stamp 9 performs a single stamping action. The single stamping action creates a first hole 20 through the lower valve layer 2 about 4 cm from the channel inlet 17 substantially in line with the channel 18, and a second hole 21 through the lower balloon layer 5 substantially concentric with the first hole 20. The holes 20,21 are formed with the punch 11. The heat sealing stamp 9 also bonds the lower valve layer 2 to the lower balloon layer 5 around the circumference of the holes 20 and 21 producing an airtight seal. The airtight seal is formed with the heating element 10. Alternatively, the heating element 10 can heat the punch 11 such that when the punch 11 forms the holes 20,21 it also heat seals the lower valve layer 2 to the lower balloon layer 5.

The folded portion of the upper valve layer 1 is returned by folding through approximately 1 90 degrees such that it is superimposed upon the lower valve layer 2 again.

Since the lower balloon layer 5 is attached to the lower valve layer 2 these materials are fed through the remainder of the manufacturing system at substantially the same speed.

An upper balloon layer 7, having a first longitudinal edge 7a, is then superimposed onto the lower balloon layer 5, sandwiching the upper and lower valve layers 1,2 in between the balloon layers 5,7 (see Figure 4b). The upper balloon layer 7 is made from the same material and has the same dimensions as the lower balloon layer 5. The upper balloon layer 7 is superimposed onto the lower balloon layer 5 such that first longitudinal edges 5a, 7a are substantially aligned. The first longitudinal edges la, 2a of valve layers 1,2 can also be

substantially aligned with the first longitudinal edge 7a of the upper balloon sheet 7. tp c

Alternatively, the first longitudinal edges 5a, 7a can be substantially aligned and the first longitudinal edges 1 a, 2a are substantially parallel to the first longitudinal edges 5a, 7a and are offset from the first longitudinal edges 5a, 7a by a short distance, for example 5 cm, such that the upper and lower valve layers 1, 2 are sandwiched between the upper and lower balloon layers 5,7.

The balloon shaping device 22 is activated each time the channel 18 between the upper and lower valve layers 1,2 and one of the holes 20,21 in the lower valve layer 2 and lower balloon layer 5 respectively is aligned with the balloon shaping device 22.

The balloon shaping device 22 is used to bond portions of the balloon layers 5,7 together to define the shape of a balloon 5c, 7c by producing an airtight seal 23 (see Figures 4a, 4b and 5). The balloon shaping device 22 includes a heating element that, together with the application of pressure, heat seals the balloon layers 5,7 together. The balloon shaping device 22 also seals portions of the upper and lower valve layers 1,2 together and bonds the lower valve layer 2 to the lower balloon layer 5 and the upper valve layer 1 to the upper valve layer 7 (see feature 23b in Figures 4a and 5).

Preferably, the balloon shaping device 22 is arranged to produce a seal 23a that overlaps the zv bonds 16 close to the valve inlet 17. This ensures the efficient operation of the valve. Webbing 24 on both sides of the channel 18 is produced when defining the balloon shape

with the balloon shaping device 22 (see Figure 5). The webbing 24 comprises portions of 1-1 the upper and lower valve layers 1,2 bonded to each other and/or portions of the upper and lower valve layers 1, 2 bonded to portions of the upper and lower balloon layers 5,7.

Material (generally indicated as 7d in Figure 4a) not included in the balloon shape 5c, 7c is

removed by additional trimming equipment included in the manufacturing system. tD Alternatively, the excess material 7d can be removed as part of the balloon shaping device sealing 22 action.

The manufacturing system operates continuously and can produce many hundreds of balloons per hour.

It will be appreciated by the skilled man that changes can be made to the embodiment described above without departing from the spirit of the present invention. For example, the bonds do not have to be formed by fusing the materials by heat sealing. They can be produced by using an adhesive or a heat activated cohesive. Also, a hole can be formed in the upper valve layer 1 instead of the lower valve layer 2 and the orientation of the sheet materials and the relative positions of the bonding apparatus can be changed. Furthermore, a cutting operation could be included to trim upper and lower valve layers 1,2 to remove at least part of the webbing 24. A further alternative is that webbing 24 may be included on only one side of the channel 18.

The lower valve layer 2 can be bonded to the lower balloon layer 5 to prevent gas escaping between those layers without sealing around the circumference of the holes 20,21. For example, a bond can be made between the layers 2,5 across the neck 27 located between the holes 20,21 and the main body of the balloon 28.

Components with combined functions, such as the heat sealing stamp 9, can be split into separate devices, i. e. a separate heat sealing device 10 and a stamping device 11. Additional bonding and stamping processes may also be incorporated. For example, two stamping devices 11 can be used, one stamp for the lower valve layer 2 and another stamp for the lower balloon layer 5.

As another alternative, the upper and lower valve layers 1,2 can be stored on separate rolls or the first and second balloon layers 5, 7 can be stored on the same roll. Also, different

arrangements of sheet material feeding mechanisms can be used. t It will also be appreciated that the order in which the individual operations are carried out can be changed without departing from the spirit of the invention and that other materials

having similar properties can be used for the balloon and valve layers. z : l It will be further appreciated that due to manufacturing tolerances, when the balloon is fully 0 formed holes 20 and 21 may not be fully concentric due to relative movement between the lower valve layer 2 and the lower balloon layer 5 during the manufacturing process.

However, the holes 20 and 21 will be sufficiently concentric to allow an inflation device to penetrate the balloon and to inflate the balloon.

Claims 1. A balloon including a first balloon layer and a second balloon layer wherein portions of the first and second balloon layers are bonded together at their edges to form a sealed balloon envelope, and further including a self-sealing valve located between said first and second balloon layers, said valve having a first valve layer and a second valve layer wherein portions of the first and second valve layers are bonded together to form a channel having an inlet and an outlet, and further including a first hole formed in the first valve layer in communication with the channel inlet and a second hole formed in the first balloon layer providing access to the first hole, wherein the first balloon layer and the first valve layer are sealed to one another to prevent gas escaping from the balloon between those layers.

2. A balloon according to claim 1, in which peripheral portions of said valve layers are sealed between peripheral portions of said balloon layers.

3. A balloon according to claim 1 or claim 2, including webbing between the channel and peripheral portions of said balloon layers.

4. A balloon according to claim 3, wherein portions of at least one of the first and second valve layers form the webbing between the channel and peripheral portions of said balloon layers.

5. A balloon according to any one of the preceding claims, wherein the first valve layer is bonded to the first balloon layer, and the second valve layer is bonded to the second balloon layer at the edges of the layers.

6. A balloon according to any one of the preceding claims, wherein the first and second holes are substantially concentric.

7. A balloon according to any one of the preceding claims, having a main body portion Z : 3 17) and a neck portion, said neck portion including a mouth that is contiguous with the main body portion and wherein the channel inlet is contiguous with the mouth and the channel is located substantially within the main body portion.

8. A balloon according to any one of the preceding claims, wherein the first balloon layer and the first valve layer are sealed to one another around the circumference of the first and second holes.

9. A manufacturing system for producing balloons having self-sealing valves, the manufacturing system including : a feeding mechanism for feeding a plurality of plastics web materials including first and second valve layers and first and second balloon layers; means for bonding together said first and second valve layers to form a self-sealing valve having an inlet, a channel and an outlet; means for forming a first hole in the first valve layer and means for forming a second hole in the first balloon layer; means for bonding together the first balloon layer and the first valve layer to prevent gas escaping from the balloon between those layers; and means for bonding said first and second balloon layers together to form a peripheral seal, with the first and second valve layers located between the first and second balloon layers.

10. A manufacturing system according to claim 9, wherein the first and second holes are formed substantially concentrically.

11. A manufacturing system according to claim 9 or claim 10, wherein the first and

second holes are formed in a single operation. z : l 12. A manufacturing system according to any one of claims 9 to 11, wherein the means for bonding together the first balloon layer and the first valve layer is incorporated with the hole forming means, such that a single operation of the combined means forms the first and second holes and bonds together the first balloon layer and the first valve layer.

13. A manufacturing system according to any one of claims 9 to 12, including a z : l t, separating device to separate portions of the superimposed valve layers which have not been bonded together, preferably the separating device folds a portion of the z : l second valve layer through an angle of approximately 90 degrees.

ZI., Llr 14. A manufacturing system according to any one of claims 9 to 13, wherein the means z ; l for bonding said first and second balloon layers together bonds portions of at least one of the valve layers to at least one of the balloon layers.

15. A manufacturing system according to any one of claims 9 to 14, wherein portions of at least one of the valve layers form webbing between the self-sealing valve and the balloon layers.

16. A manufacturing system according to any one of claims 9 to 15, wherein the means Z > for bonding together the first balloon layer and the first valve layer forms an airtight C) c seal around the circumference of the first and second holes.

17. A method of manufacturing balloons having self-sealing valves, the method including the steps: superimposing a first valve layer onto a second valve layer; bonding together portions of the first and second valve layers to form a channel, said channel having an inlet and an outlet; superimposing the first and second valve layers onto a portion of a first balloon layer; forming a first hole through the first valve layer; forming a second hole through the first balloon layer; bonding portions of the first valve layer to portions of the first balloon layer to form an airtight seal to prevent gas escaping from the balloon between those layers; superimposing a second balloon layer onto the first balloon layer locating the first and second valve layers there between; and bonding portions of the first and second balloon layers together to form an airtight seal around the periphery of the balloon.

18. A method according to claim 17, wherein the first and second holes are formed substantially concentrically.

19. A method according to claim 17 or claim 18, including the additional step of separating portions of the first and second valve layers not bonded together.

20. A method according to any one of claims 17 to 19, wherein the width of the balloon layers is greater than the width of the valve layers.

21. A method according to claim 20, wherein the ratio of the width of the balloon layers to the width of the valve layers is in the range of 1: 2 to 1: 5, and is preferably approximately 1: 3.

22. A method according any one of claims 17 to 21, wherein the first and second holes are formed by a single operation.

23. A method according to any one of claims 17 to 22, wherein the step of bonding portions of the first balloon layer to portions of the first valve layer is performed substantially simultaneously with the hole forming operation.

24. A method according to any one of claims 17 to 23, wherein the method is performed by a substantially continuous manufacturing process.

25. A method according to any one of claims 17 to 24, wherein the step of bonding portions of the first valve layer to portions of the first balloon layer forms an airtight seal around the circumference of the first and second holes.

26. A balloon having a self-sealing valve made in accordance with any one of the preceding claims.

27. A valve for a balloon including a first valve layer and a second valve layer wherein portions of the first and second valve layers are bonded together to form a channel

having an outlet and an inlet, and wherein a hole is formed in the first valve layer C7, close to and substantially in line with the channel.

28. A valve for a balloon according to claim 27, wherein portions of at least one of the first and second valve layers form webbing on at least one side of the channel.

29. A valve for a balloon according to claim 28, wherein the webbing is arranged for attachment to at least one balloon layer.

30. A balloon substantially as described herein with reference to the accompanying drawings.

31. A method and a manufacturing system for producing a balloon substantially as

described herein with reference to the accompanying drawings. t > z, 32. A valve substantially as described herein with reference to the accompanying drawings.

Claims

Amendments to the claims have been filed as follows Claims 1. A balloon including a first balloon layer and a second balloon layer wherein portions of the first and second balloon layers are bonded together at their edges to form a

sealed balloon envelope, a self-sealing valve located between said first and second z balloon layers, said valve having a first valve layer and a second valve layer wherein y =1 portions of the first and second valve layers are bonded together to form a channel having an inlet and an outlet, webbing between the channel and peripheral portions of said balloon layers, a first hole formed in the first valve layer in communication with the channel inlet, a second hole formed in the first balloon layer providing access to the first hole, wherein the first balloon layer and the first valve layer are sealed to one another to prevent gas escaping from the balloon between those layers.
2. A balloon according to claim 1, in which peripheral portions of said valve layers are sealed between peripheral portions of said balloon layers.
3. A balloon according to claim 1 or claim 2, wherein portions of at least one of the first and second valve layers form the webbing between the channel and peripheral portions of said balloon layers.
4. A balloon according to any one of the preceding claims, wherein the first valve layer is bonded to the first balloon layer, and the second valve layer is bonded to the second balloon layer at the edges of the layers.
5. A balloon according to anyone of the preceding claims, wherein the first and second holes are substantially concentric.
6. A balloon according to any one of the preceding claims, having a main body portion and a neck portion, said neck portion including a mouth that is contiguous with the main body portion and wherein the channel inlet is contiguous with the mouth and the channel is located substantially within the main body portion.
7. A balloon according to any one of the preceding claims, wherein the first balloon layer and the first valve layer are sealed to one another around the circumference of the first and second holes.

<Desc/Clms Page number 18>
8. A manufacturing system for producing balloons having self-sealing valves, the manufacturing system including : a feeding mechanism for feeding a plurality of plastics web materials including first and second valve layers and first and second balloon layers; means for bonding together said first and second valve layers to form a self-sealing valve having an inlet, a channel and an outlet ; means for forming a first hole in the first valve layer and means for forming a second hole in the first balloon layer ; means for bonding together the first balloon layer and the first valve layer to prevent gas escaping from the balloon between those layers ; and means for bonding said first and second balloon layers together to form a peripheral seal, with the first and second valve layers located between the first and second balloon layers, wherein the feeding mechanism is constructed and arranged to superimpose the first and second valve layers onto a portion of the first balloon layer.
9. A manufacturing system according to claim 8, wherein the first and second holes are formed substantially concentrically.
10. A manufacturing system according to claim 8 or claim 9, wherein the first and

second holes are formed in a single operation. z : l
11. A manufacturing system according to any one of claims 8 to 10, wherein the means for bonding together the first balloon layer and the first valve layer is incorporated with the hole forming means, such that a single operation of the combined means forms the first and second holes and bonds together the first balloon layer and the first valve layer.
12. A manufacturing system according to any one of claims 8 to 11, including a separating device to separate portions of the superimposed valve layers which have not been bonded together, preferably the separating device folds a portion of the second valve layer through an angle of approximately 90 degrees.
13. A manufacturing system according to any one of claims 8 to 12, wherein the means for bonding said first and second balloon layers together bonds portions of at least one of the valve layers to at least one of the balloon layers.

<Desc/Clms Page number 19>
14. A manufacturing system according to any one of claims 8 to 13, wherein portions of at least one of the valve layers form webbing between the self-sealing valve and the balloon layers.
15. A manufacturing system according to anyone of claims 8 to 14, wherein the means

for bonding together the first balloon layer and the first valve layer forms an airtight Z, I 1- seal around the circumference of the first and second holes.
16. A method of manufacturing balloons having self-sealing valves, the method including the steps : superimposing a first valve layer onto a second valve layer ; bonding together portions of the first and second valve layers to form a channel, said channel having an inlet and an outlet; superimposing the first and second valve layers onto a portion of a first balloon layer ; forming a first hole through the first valve layer ; forming a second hole through the first balloon layer ; bonding portions of the first valve layer to portions of the first balloon layer to form an airtight seal to prevent gas escaping from the balloon between those layers ; superimposing a second balloon layer onto the first balloon layer locating the first and second valve layers there between ; and bonding portions of the first and second balloon layers together to form an airtight seal around the periphery of the balloon.
17. A method according to claim 16, wherein the first and second holes are formed substantially concentrically.
18. A method according to claim 16 or claim 17, including the additional step of separating portions of the first and second valve layers not bonded together.
19. A method according to any one of claims 16 to 18, wherein the width of the balloon layers is greater than the width of the valve layers.
20. A method according to claim 19, wherein the ratio of the width of the balloon layers to the width of the valve layers is in the range of 1 : 2 to 1 : 5, and is preferably approximately 1 : 3.
21. A method according any one of claims 16 to 20, wherein the first and second holes are formed by a single operation.

<Desc/Clms Page number 20>
22. A method according to any one of claims 16 to 21. wherein the step of bonding portions of the first balloon layer to portions of the first valve layer is performed substantially simultaneously with the hole forming operation.
23. A method according to any one of claims 16 to 22, wherein the method is performed by a substantially continuous manufacturing process.
24. A method according to any one of claims 16 to 23, wherein the step of bonding =1 I portions of the first valve layer to portions of the first balloon layer forms an airtight seal around the circumference of the first and second holes.
25. A balloon having a self-sealing valve made in accordance with any one of the

preceding claims. z
26. A balloon substantially as described herein with reference to the accompanying drawings.
27. A manufacturing system for producing a balloon substantially as described herein

with reference to the accompanying drawings. incs.
28. A method for producing a balloon substantially as described herein with reference to the accompanying drawings.