Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64B—LIGHTER-THAN AIR AIRCRAFT
  • B64B1/00—Lighter-than-air aircraft
  • B64B1/06—Rigid airships; Semi-rigid airships
  • B64B1/14—Outer covering
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64B—LIGHTER-THAN AIR AIRCRAFT
  • B64B1/00—Lighter-than-air aircraft
  • B64B1/40—Balloons
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64B—LIGHTER-THAN AIR AIRCRAFT
  • B64B1/00—Lighter-than-air aircraft
  • B64B1/58—Arrangements or construction of gas-bags; Filling arrangements
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
  • B64D27/00—Arrangement or mounting of power plants in aircraft; Aircraft characterised by the type or position of power plants
  • B64D27/02—Aircraft characterised by the type or position of power plants
  • B64D27/30—Aircraft characterised by electric power plants
  • B64D27/35—Arrangements for on-board electric energy production, distribution, recovery or storage
  • B64D27/353—Arrangements for on-board electric energy production, distribution, recovery or storage using solar cells
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B64—AIRCRAFT; AVIATION; COSMONAUTICS
  • B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
  • B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
  • B64F5/10—Manufacturing or assembling aircraft, e.g. jigs therefor

Definitions

• the present invention relates to a method for manufacturing an envelope comprising solar cells configured for use in an aerostat balloon.
• the present invention further relates to an envelope comprising solar cells for an aerostat balloon and to an aerostat comprising such an envelope.
• the term “balloon” refers to the volume having an elongated shape delimited by an envelope, the balloon being the element of the aerostat that provides lift and carries the load such as the gondola.
• envelope refers to the laminate material delimiting the balloon.
• Aerostats are known in the prior art.
• An aerostats is a lighter than air aircraft that gains its lift through the use of a buoyant gas contained in the aerostat balloon.
• Aerostats according to the present invention comprise both aerostats having horizontally and vertically elongated balloons.
• aerostat envelopes which comprise solar cells such as to harness solar energy and to convert it into electrical energy used amongst others to propel electrical motors provided on the aerostat.
• solar cells such as to harness solar energy and to convert it into electrical energy used amongst others to propel electrical motors provided on the aerostat.
• each base sheet strip is a portion of a base sheet of the envelope, wherein each base sheet strip is delimited by a first major surface and an opposing second major surface, wherein each base sheet strip comprises an airtight layer configured to maintain air within the aerostat balloon, and wherein some of the base sheet strips comprise a solar part substantially centrally disposed on the base sheet strip, the solar part being the part of the base sheet arranged to be in the solar section of the envelope,
• the functional sheet comprising a flexible solar cell layer comprising multiple solar cells
• the present invention provides a method for manufacturing an envelope for an aerostat balloon according to the first claim.
• the method comprises a series of steps that result in a finished envelope which, after inflation, has a convex outer surface, a concave inner surface and an elongated shape which extends in an axial direction, perpendicular to a circumferential direction and a radial direction, between a first ending and a second ending.
• the reference to the “elongated shape” preferably refers to the above mentioned elongated shape of the inflated finished envelope.
• the finished envelope comprises a solar section configured to function as a solar energy generator. The present method enables to provide the solar section at least adjacent to the first and/or second ending of the finished envelope.
• the method comprises the consecutive steps of: a) providing a base sheet of the envelope, wherein the base sheet is delimited by a first major surface and an opposing second major surface, wherein the base sheet is arranged to be inflated into the elongated shape of the finished envelope such that the first major surface is a convex surface and the second major surface is a concave surface, wherein the base sheet comprises an airtight layer configured to maintain air within the aerostat balloon, and wherein the base sheet comprises a solar part arranged to be in the solar section of the envelope, b) deforming the base sheet into the elongated shape i.e.
• the lamination comprises providing a plurality of strips arranged to be interconnected into the functional sheet, wherein each strip has a length delimited by opposing short sides that is larger than their width delimited by opposing long sides, and wherein the strips are laminated onto the convex outer surface of the deformed solar part such that each strip is interconnected to a neighboring strip at at least one of their long sides, and such that the long sides of the envelope strips are disposed along the circumferential direction of the elongated shape.
• the method of the present invention enables to provide the solar section at least adjacent to the first and/or second ending of the finished envelope i.e. in addition to the provision of the solar section on the bulk of the envelope between the first ending and the second ending.
• the method of the state of the art does not enable to provide the solar section at least adjacent to the first and/or second section.
• assembly strips are cut out of the base sheet strips, wherein the assembly strips have only two edges terminating in a fore and aft terminal. It is thus impossible in the state of the art to provide the solar part into the sections of the base sheet strips adjacent to the aft and fore terminals, because any functional sheet laminated onto those sections would be damaged by the cutting of the base sheet.
• the solar parts are confined to the central portion of the base sheets between the fore and aft terminals where the two edges of the assembly strip are substantially parallel to each other.
• the present invention has the further advantage that the solar cells are closer packed than in the prior art. Indeed, in the prior art assembly strips are formed which are subsequently deformed into the elongated shape upon inflation of the envelope. Due to this deformation the assembly strips will be slightly stretched. Due to this stretching the distance between the solar cells will increase, thus leading to a loss of covered envelope area.
• the method of the present invention enables to apply the functional sheet onto a deformed and thus slightly stretched base sheet. The functional sheet thus does not require stretching, thus leading to a closer packing of the solar cells.
• the present advantage further increase power output and flight speed
• the present invention has the further advantage that the solar cells cover a greater surface area of the envelope than in the prior art. Indeed in the prior art assembly strips need to be interconnected to each other. This requires distancing the solar part of the base strips from the edges of the assembly strip such as to enable jointing two assembly strips to one another without damaging the functional sheet in the assembly strip, i.e. enabling the edges of adjacent assembly strips to be joined for example by thermal fusion, without impacting any functional sheet that would be present adjacent to the assembly strip edge.
• the method of the prior art thus yields an envelope wherein the solar section is not onto the assembly strip joints.
• the method of the present invention comprises laminating a functional sheet onto pre-assembled parts of the base sheet, i.e.
• the present invention thus enables to provide the solar parts of the base sheet onto these joints and onto the area adjacent to those joints, and thus providing the solar section of the envelope also onto these joints and the area adjacent to these joints.
• the present advantage further increases power output and flight speed.
• substantially the entire assembled base sheet is provided in step a) and subsequently deformed in step b).
• the base sheet provided in step a) comprises multiple separate but interconnectable parts, for example less than five separate but interconnectable parts, wherein each part preferably comprises several interconnected elongated base sheet strips, and the step b) comprises deforming the separate parts of the base sheet into the corresponding parts of the elongated shape, and step c) is applied to each of the separate interconnectable deformed parts.
• the separate interconnectable deformed parts are interconnected after step c).
• embodiments of the present invention yield an aerostat balloon having increased aerodynamic performance by providing a substantially smooth convex outer surface of the finished envelope by reducing the amount of sharp transitions between sections forming the convex outer surface of the finished envelope.
• the present invention discloses two alternative methods for yielding such a finished envelope, as described below under the “first alternative embodiment” and the “second alternative embodiment”.
• the convex outer surface of the solar part that is laminated in step c) corresponds to the first major surface of the solar part, and the second major surface of the solar part is part of the concave inner surface of the finished envelope.
• the method comprises a further lamination step after step c), wherein the further lamination step comprises laminating a cover layer onto at least the functional sheet applied onto the outer convex surface of the deformed solar parts.
• the further lamination step comprises laminating the cover layer onto the functional sheet applied onto the convex outer surface of the deformed solar parts, as well as onto the outer convex surface of the deformed parts of the base sheet that are not solar parts.
• the further lamination is such that the entire finished envelope is covered by the cover layer at its convex outer surface.
• the present first alternative method ensures that a smooth convex outer surface of the envelope is obtained.
• the cover layer smooths over any sharp transitions between the strips of the functional sheet.
• the cover layer additionally smooths over any sharp transitions between the functional sheet in the solar parts of the base sheet and the parts of the base sheet not being a solar part.
• the further lamination step is only performed after assembling/interconnecting the separate deformed parts of the base sheet into the elongated shape after step c). This ensures that any sharp transitions between parts interconnected deformed parts are smoothened out.
• the method further comprises a first reversal step between steps a)- c), wherein the first reversal step comprises pulling the base sheet inside out such that after step b) but prior to step c) the second major surface of the deformed solar part forms a convex outer surface, and that the opposing first major surface of the deformed solar part forms a concave inner surface, wherein the convex outer surface of the solar parts that are laminated in step c) corresponds to the second major surface of the solar part, wherein the method further comprises a second reversal step after step c), wherein the second reversal step comprises pulling the base sheet inside out such that the first major surface of the deformed solar part forms a convex outer surface, and that the opposing second major surface of the deformed solar part forms a concave inner surface, and wherein the first major surface of the solar part forms the convex outer surface of the finished envelope.
• the first reversal step comprises pulling the base sheet inside out such that after step b) but prior to
• the smooth outer convex surface of the envelope is obtained by pulling the envelope inside out such that the functional sheet is on the inside of he finished envelope and the base sheet is on the outside of the finished envelope.
• the base sheet is preferably substantially transparent to visible light, preferably to light having a wavelength between 300nm and 1200nm. This ensures that light reaches the solar cells in the functional sheet.
• the base sheet provided in step a) preferably comprises a hole allowing the performance of the first reversal step and the second reversal step, and wherein the method further comprises covering the hole after performing the second reversal step.
• the hole is for example the omission of one base sheet strip in the otherwise integrally assembled base sheet.
• the method comprises a further lamination prior to step c), wherein the further lamination step comprises laminating a cover layer onto at least the outer convex surface of the deformed solar parts such that the cover layer becomes part of the base sheet.
• This further lamination step ensures that the solar cells in the functional sheet are separated from the base sheet by a cover layer.
• the deformation in step b) comprises one of inflating the base sheet or deforming the base sheet with a deformer, wherein the deformer is preferably an inflated element.
• the base sheet provided in step a) comprises separate interconnectable parts as described above, the base sheet is preferably deformed by using a former.
• the width of adjacent strips decreases from a widest strip positioned closest to the axial position centrally between the first ending and second ending of the finished envelope towards the strip closest to the first or second end of the finished envelope.
• the present embodiment has the advantage that the functional strips provided in the described manner best follow the curved contours of the elongated shape. Indeed, at the central location between the first and second endings of the finished envelope, the curvature of the elongated shape, in particular around an axis perpendicular to the axial direction, is smallest.
• the strips are substantially rectangular strips.
• the solar cells comprises in the rectangular strips are rectangular solar cells.
• the strips are curved around an axis perpendicular to the plane of the strip, wherein preferably the curvature increases from a substantially un-curved strip positioned closest to the axial position centrally between the first ending and second ending of the finished envelope towards the strip closest to the first or second end of the finished envelope.
• the length of the strips substantially correspond to the circumferential length of the elongated shape at the position where the strip is laminated onto the base sheet.
• the cover layer as described above is substantially transparent to visible light, preferably to light having a wavelength between 300nm and 1200nm. This embodiment ensures that light reaches the solar cells.
• the further lamination step i.e. the application of the cover layer as described above, comprises depositing the cover layer in a liquid phase.
• p re-formed sheets of cover layer material are applied in the further lamination step.
• the solar section comprises a first section provided adjacent to the first ending and a second section provided at the second ending, and wherein the solar section further comprises an interconnecting section interconnecting the first section and the second section.
• the embodiment is particularly advantageous for horizontally elongated aerostat balloons, i.e. a balloon configured for holding a gondola at a position of the elongated shape between the first and second endings.
• the interconnecting section of the solar section is provided at the side of the elongated shape opposite to the side on which the gondola is provided.
• the gondola is after all typically provided “below” the balloon, i.e. between the balloon and the earth.
• the solar section comprises only one of the first section provided adjacent to the first ending or the second section provided adjacent to the second ending of the elongated shape, i.e. not both the first and second sections respectively provided adjacent to the first and second endings.
• This embodiment however preserves the option that the solar section comprises a section intermediate the first and second endings of the elongated shape.
• This alternative embodiment is particularly advantageous for vertically elongated aerostat balloons, i.e. a balloon configured for holding a gondola at the first or second endings.
• the solar section comprises only the first ending, i.e.
• the solar section covers at least 30%, preferably at least 40% of the envelope surface.
• the elongated shape of the finished envelope in particular when the envelope is for a horizontally elongated aerostat balloon, is an ellipsoid, preferably a sferoide, more preferably a prolate sferoide.
• the aerostat balloon is a balloon for a non-rigid aerostat.
• the aerostat balloon is a balloon for a vertically elongated aerostat as described above. According to an alternative embodiment, the aerostat balloon is a balloon for a horizontally elongated aerostat as described above.
• Figure 1 shows a perspective view of two different types of aerostat, i.e. a vertically elongated aerostat and a horizontally elongated aerostat.
• Figures 2-6 show method steps according to a first implementation of the method of the present invention.
• Figure 2 shows the cross section of the envelope obtained by the first implementation of the method of the present invention.
• Figure 3 shows the first step of providing a base sheet comprising solar parts and of deforming the base sheet into the elongated shape of the final envelope.
• Figure 3A shows a perspective view of the method step.
• Figure 3B shows a cross section of the envelope obtained by this first step, wherein the accolade to the right of the cross- section indicates the layers primarily involved in the present step of the method.
• Figure 4 shows the second step of laminating a functional sheet onto the solar parts of the base sheet.
• Figure 4A shows a perspective view of the method step.
• Figure 4B shows a cross section of the envelope obtained by this second step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figures 4C and 4D show a detailed top view of the flexible solar cell layer respectively positioned in an axially central position between the first and second ending, and in a position adjacent to the second ending.
• Figure 4E shows a further detailed view of the detailed view shown in 4D.
• Figures 5 and 6 show two alternative third steps of the first implementation of the method, wherein a cover sheet is applied.
• Figure 5 shows the application of pre-form ed cover sheet strips.
• Figure 5A shows a perspective view of the method step.
• Figure 5B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 6 shows the application of the cover sheet by liquid deposition.
• Figure 6A shows a perspective view of the method step.
• Figure 6B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figures 7-12 show method steps according to a second implementation of the method of the present invention.
• Figure 7 shows the cross section of the envelope obtained by the second implementation of the method of the present invention.
• Figure 8 shows the first step of providing a base sheet with hole, the base sheet comprising both an airtight layer and a cover layer, and of deforming the base sheet into the elongated shape of the final envelope.
• Figure 8A shows a perspective view of the method step.
• Figure 8B shows a cross section of the envelope obtained by this first step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 9 shows the second step of turning the base sheet inside out through the hole.
• Figure 9A shows a perspective view of the method step.
• Figure 9B shows a cross section of the envelope obtained by this second step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 10 shows the third step of laminating a functional sheet onto the solar parts of the base sheet, wherein the functional sheet comprises both a flexible solar cell layer and a solar panel support layer.
• Figure 10A shows a perspective view of the method step.
• Figure 10B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figures 10C and 10D show a detailed top view of the flexible solar cell layer respectively positioned in an axially central position between the first and second ending, and in a position adjacent to the second ending.
• Figure 10E shows a further detailed view of the detailed view shown in 10D.
• Figure 11 shows the fourth step of turning the laminated base sheet and functional sheet inside out through the hole.
• Figure 11 A shows a perspective view of the method step.
• Figure 11 B shows a cross section of the envelope obtained by this fourth step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 12 shows the fifth step of covering the hole in the envelope.
• Figure 12A shows a perspective view of the method step.
• Figure 12B shows a cross section of the envelope obtained by this fifth step, wherein the accolade to the right of the cross- section indicates the layers primarily involved in the present step of the method.
• the present invention is directed to a method for manufacturing an envelope 1 for an aerostat balloon, the finished envelope after inflation having a convex outer surface 2, a concave inner surface 3 and an elongated shape which extends in an axial direction 5, perpendicular to a circumferential direction and a radial direction, between a first ending 6 and a second ending 7.
• Figure 1 shows a perspective view of two different types of aerostat balloons wherein the finished envelope 1 is inflated to the elongated shape corresponding to the type of aerostat balloon, i.e. a vertically elongated aerostat balloon 8 and a horizontally elongated aerostat balloon 9.
• a horizontally elongated aerostat balloon 9 is a balloon configured for holding a gondola at a position of the elongated shape between the first 6 and second endings 7.
• the gondola (not shown) is typically provided “below” the balloon, i.e. between the balloon and the earth.
• the side opposite that on which the gondola is provided is the side most exposed to the sun, as shown by the arcing of the envelope in the figure.
• a vertically elongated aerostat balloon 8 is a balloon configured for holding a gondola at the first or second endings, here shown at the second ending 7.
• the gondola (not shown) is typically provided “below” the balloon, i.e. between the balloon and the earth.
• the first ending 6 being opposite to the second ending 7 is the side most exposed to the sun, as shown by the arcing of the envelope in the figure.
• the embodiments described below are exemplified based on a horizontally elongated aerostat balloon 9, but are equally applicable to vertically elongated aerostat balloons 8.
• Figures 2-6 show method steps according to a first implementation of the method of the present invention.
• FIG. 2 shows the cross section of the envelope obtained by the first implementation of the method of the present invention.
• the finished envelope 1 comprises a base sheet 10 and, on certain sections of the base sheet 10, referred to as solar parts of the base sheet 10, a functional sheet 11 laminated to the base sheet 10.
• the solar parts are chosen in function of the type of aerostat balloon, e.g. provided solely on the first ending and adjacent to the first endings for a vertically elongated aerostat balloon 8, or provided on both first and second endings as well as on interconnecting parts between those endings for a horizontally elongated aerostat balloon 9.
• the solar parts 5 of the base sheet 10 laminated with the functional sheet 11 form the solar sections of the finished envelope 1.
• the finished envelope 1 comprises, in addition to the base sheet 10 and the functional sheet 11 , a cover sheet 15 consisting of a cover layer 16.
• the cover layer 16 is transparent to visible light, such as to enable solar radiation to reach the solar cells in the functional ID sheet 11.
• the cover layer 16 forms the smooth convex outer surface 2 of the finished envelope.
• the base sheet 10 comprises an airtight layer 12 for maintaining gas inside of the envelope 1.
• the airtight layer 12 forms the concave inner surface 3 of the finished envelope 1.
• the functional sheet 11 comprises at least a flexible solar cell layer 13 comprising multiple rectangular solar cells arranged to convert solar radiation 15 into electrical energy.
• the functional sheet 11 further comprises a solar cell support layer 14 configured for supporting the functioning of the solar cells in the flexible solar cell layer 13.
• the solar cell support layer 14 for example comprises the wiring circuits for harnessing the generated electrical energy by the flexible solar cell layer 13.
• the solar cell support layer 14 is comprised in the base layer 10, i.e. is laminated to the airtight layer 12 prior to the performance of the first step of the present implementation of the method according to the invention.
• Figure 3 shows the first step of providing the above mentioned base sheet 10 25 comprising only the airtight layer 12, and of deforming the base sheet 10 into the elongated shape of the final envelope.
• Figure 3A shows a perspective view of the method step.
• Figure 3B shows a cross section of the envelope obtained by this first step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• the first step comprises providing 30 a plurality of base sheet strips 26 each delimited by only two edges terminating in a fore terminal 17 and aft terminal 18.
• the first step further comprises interconnecting the plurality of base sheet strips 26 into the base sheet 10 by attaching the edges of neighboring strips to one another such that all the fore terminals 17 terminate in the first ending 6 of the envelope 1 and that all the aft terminals 18 terminate in the second ending 7 of the envelope 1 .
• the base sheet 10 is deformed into the elongated shape of the final envelope.
• Figure 4 shows the second step of laminating the functional sheet 11 onto the solar parts of the base sheet 10.
• Figure 4A shows a perspective view of the method step.
• the solar part of the base sheet comprises the entire upper side of the elongated shape between the first ending 6 and the second ending 7 thereby covering approximately 50% of the envelope surface.
• the solar part in particular comprises the part of the deformed base sheet 10 that lies on one side of a plane comprising the axis interconnecting the first ending 6 and the second ending 7.
• Figure 4B shows a cross section of the envelope obtained by this second step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• FIGs 4C and 4D show a detailed top view of the flexible solar cell layer 13 comprising rectangular solar cells 19, wherein the top view is respectively taken in an axially central position between the first and second ending 6, 7, and in a position adjacent to the second ending 7.
• the flexible solar cell layer 13 is formed by a plurality of rectangular solar cell strips 20.
• the solar cell strips 20 are rectangular strips comprising a width between opposite long sides 23, and comprising a length between opposite short sides 24.
• the flexible solar cell layer 13 is formed by interconnecting each solar cell strip 20 along at least one of their long sides 23 to the long side 23 of a neighboring solar cell strip 20.
• Figure 4A shows how the width of the solar cell strips 20 decreases from the strips positioned between the first ending 6 and the second ending 7.
• Figure 4A also shows how the solar cell strips 21 at the central position between the first ending 6 and the second ending 7 are less curved along an axis perpendicular to the plane of the strip, than the solar cell strips 22 adjacent to the first and second endings 6, 7.
• Figure 4E shows a further detailed view of the detailed view shown in 4D. From the detailed view shown in figure 4E it is visible how a minor amount of solar packing space is lost in a curved solar cell strip 22 with respect to a non-curved solar cell strip 21 (visible as a shaded area).
• Figures 5 and 6 show two alternative third steps of the first implementation of the method, wherein the cover sheet 15 comprising the cover layer 16 is applied on top of the functional layer 11.
• Figure 5 shows the application of pre-form ed cover layer strips 25 on top of the functional sheet 11.
• Figure 5A shows a perspective view of the method step.
• Figure 5B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 6 shows the application of the cover sheet 15 comprising the cover layer 16 by liquid deposition 27 on top of the functional sheet 11.
• Figure 6A shows a perspective view of the method step.
• Figure 6B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figures 7-12 show method steps according to a second implementation of the method of the present invention.
• FIG. 7 shows the cross section of the envelope obtained by the second implementation of the method of the present invention.
• the finished envelope 1 comprises a base sheet 10 and, on certain sections of the base sheet 10, referred to as solar parts of the base sheet 10, a functional sheet 11 laminated to the base sheet 10.
• the solar parts are chosen in function of the type of aerostat balloon, e.g. provided solely on the first ending and adjacent to the first endings for a vertically elongated aerostat balloon 8, or provided on both first and second endings as well as on interconnecting parts between those endings for a horizontally elongated aerostat balloon 9.
• the solar parts of the base sheet 10 laminated with the functional sheet 11 form the solar sections of the finished envelope 1 .
• the base sheet 10 comprises an airtight layer 12 for maintaining gas inside of the envelope 1 as well as a cover layer 16.
• the cover layer 16 and the airtight layer 12 are transparent to visible light, such as to enable solar radiation to reach the solar cells in the functional sheet 11.
• the presence of a cover layer is optional, but beneficial in protecting the solar cells in the functional sheet 11.
• the airtight layer 12 forms the convex outer surface 2 of the finished envelope 1.
• the functional sheet 11 comprises at least a flexible solar cell layer 13 comprising multiple rectangular solar cells arranged to convert solar radiation into electrical energy.
• the functional sheet 11 further comprises a solar cell support layer 14 configured for supporting the functioning of the solar cells in the flexible solar cell layer 13.
• the solar cell support layer 14 for example comprises the wiring circuits for harnessing the generated electrical energy by the flexible solar cell layer 13.
• the solar cell support layer 14 forms the concave inner surface 3 of the finished envelope 1 .
• Figure 8 shows the first step of providing the above mentioned base sheet 10 comprising the airtight layer 12 and the cover layer 15, and of deform ing the base sheet 10 into the elongated shape of the final envelope.
• the cover layer 15 and the airtight layer 12 are arranged such that, upon deformation of the base sheet 10 into the elongated shape, the cover layer 15 would form the concave inner surface and the airtight layer 12 would form the convex outer surface.
• Figure 8A shows a perspective view of the method step.
• Figure 3B shows a cross section of the envelope obtained by this first step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• the first step comprises providing a plurality of base sheet strips 26 each delimited by only two edges terminating in a fore terminal 17 and aft terminal 18.
• the first step further comprises interconnecting the plurality of base sheet strips 26 into the base sheet 10 by attaching the edges of neighboring strips to one another such that all the fore terminals 17 terminate in the first ending 6 of the envelope 1 and that all the aft terminals 18 terminate in the second ending 7 of the envelope 1.
• the base sheet 10 comprises a hole 27 formed by omitting one or more base sheet strips 26. This hole 27 is required for turning the base sheet 10 inside out as described below.
• the base sheet 10 is deformed into the elongated shape of the final envelope.
• the deformation of the base sheet 10 into the elongated shape of the envelope can also be performed after the second step of the present implementation of the method, i.e. after having turned the base sheet inside out. It is however important that the deformation of the base sheet 10 into the elongated shape of the final envelope takes place prior to the third step of the present implementation of the method, i.e. prior to laminating the functional layer 11 onto the solar parts of the base sheet 10.
• Figure 9 shows the second step of turning the base sheet 10 inside out through the hole 27.
• the cover layer 15 and the airtight layer 12 are arranged such that, upon deformation of the base sheet 10 into the elongated shape, the cover layer 15 would form the convex outer surface and the airtight layer 12 would form the concave inner surface.
• Figure 9A shows a perspective view of the method step.
• Figure 9B shows a cross section of the envelope obtained by this second step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 10 shows the third step of laminating the functional sheet 11 onto the solar parts of the base sheet 10.
• Figure 10A shows a perspective view of the method step.
• the solar part of the base sheet comprises the entire upper side of the elongated shape between the first ending 6 and the second ending 7 thereby covering approximately 50% of the envelope surface.
• the solar part in particular comprises the part of the deformed base sheet 10 that lies on one side of a plane comprising the axis interconnecting the first ending 6 and the second ending 7.
• Figure 10B shows a cross section of the envelope obtained by this third step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• FIGs 10C and 10D show a detailed top view of the flexible solar cell layer 13 comprising rectangular solar cells 19, wherein the top view is respectively taken in an axially central position between the first and second ending 6, 7, and in a position adjacent to the second ending 7.
• the flexible solar cell layer 13 is formed by a plurality of rectangular solar cell strips 20.
• the solar cell strips 20 are rectangular strips comprising a width between opposite long sides 23, and comprising a length between opposite short sides 24.
• the flexible solar cell layer 13 is formed by interconnecting each solar cell strip 20 along at least one of their long sides 23 to the long side 23 of a neighboring solar cell strip 20.
• Figure 10A shows how the width of the solar cell strips 20 decreases from the strips positioned between the first ending 6 and the second ending 7.
• Figure 10A also shows how the solar cell strips 21 at the central position between the first ending 6 and the second ending 7 are less curved along an axis perpendicular to the plane of the strip, than the solar cell strips 22 adjacent to the first and second endings 6, 7.
• Figure 10E shows a further detailed view of the detailed view shown in 10D. From the detailed view shown in figure 10E it is visible how a minor amount of solar packing space is lost in a curved solar cell strip 22 with respect to a non-curved solar cell strip 21 (visible as a shaded area).
• Figure 11 shows the fourth step of turning the laminated base sheet 10 and functional sheet 11 inside out through the hole 27.
• Figure 11 A shows a perspective view of the method step.
• Figure 11 B shows a cross section of the envelope obtained by this fourth step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.
• Figure 12 shows the fifth step of covering the hole 27 in the envelope by a remaining base sheet strip 26.
• Figure 12A shows a perspective view of the method step.
• Figure 12B shows a cross section of the envelope obtained by this fifth step, wherein the accolade to the right of the cross-section indicates the layers primarily involved in the present step of the method.

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• 2021
  • 2021-03-22 BE BE20215214A patent/BE1029223B1/nl active IP Right Grant
• 2022
  • 2022-03-22 WO PCT/EP2022/057434 patent/WO2022200316A1/en active Application Filing

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