How are hot air baloons made

A hot air balloon for manned flight uses a single1,000 meters (1% per 1,000 ft) of altitude gained.
layered, fabric gas bag (lifting "envelope"), with anA range of envelope sizes is available. The
opening at the bottom called the mouth. Attachedsmallest, one-person, basket-less balloons (called
to the envelope is a basket, or gondola, for"Hoppers" or "Cloudhoppers") have less than 1,000
carrying the passengers. Mounted above thecubic meters (35,000 ft3) of envelope volume. At
basket and centered in the mouth is the "burner"the other end of the scale are the balloons used
which injects a flame into the envelope, heatingby large commercial sightseeing operations that
the air within. Raising the air temperature insidecarry well over two dozen people and have
the envelope makes it lighter than the surroundingenvelope volumes of up to 15,000 cubic meters
(ambient) air. This causes the balloon and its(600,000 ft3). However, most balloons are roughly
payload to rise.2,500 cubic meters (100,000 ft3) and carry 3 to
Modern hot air balloons are usually made of4 people.
synthetic fabrics such as ripstop nylon, a lightThe Rozier type of hybrid balloon, called after its
weight fabric of high strength. During thecreator, Jean-Francois Pilatre de Rozier, has
manufacturing process, the material is cut intoseparate cell for helium as well as a cone below
panels and sewn together, along with structuralfor hot air (as is used in a hot air balloon) to heat
load tapes (webbing) that carry the weight of thethe helium at night.
gondola or basket. The heater or burner is fueledThe direction of flight depends on the wind, but
by propane, a liquefied gas stored in pressurethe altitude of the balloon can be controlled by
vessels, similar to high pressure forklift cylinders.changing the temperature of the air inside the
The amount of lift (or buoyancy) provided by aenvelope.
hot air balloon depends primarily upon theThe top of the balloon usually has a vent of some
difference between the temperature of the airsort. The most common type of vent is a
inside the envelope and the temperature of thedisk-shaped flap of fabric called a parachute vent.
air outside the envelope. For most envelopesThe fabric is connected around its edge to a set
made of nylon fabric, the maximum internalof "vent lines" that converge in the center. (The
temperature is limited to approximately 120arrangement of fabric and lines looks roughly like
°C (250 °F). It should be noted that thea parachute -- thus the name.) These "vent lines"
melting point of nylon is significantly higher thanare themselves connected to a control line that
these maximum operating temperature -- aboutruns to the basket. A parachute vent is opened
230 °C (450 °F). However the lowerby pulling on the control line. Once the control line
temperatures are generally used because theis released, the pressure of the remaining hot air
higher the temperature, the more quickly thepushes the vent fabric back into place. A
strength of the nylon fabric degrades over time.parachute vent can be opened briefly while in
With a maximum operating temperature of 120flight to initiate a rapid descent. (Slower descents
°C, balloon envelopes can generally be flownare initiated by allowing the air in the balloon to
for between 400 and 500 hours before the fabriccool naturally.) The vent is pulled completely open
needs to be replaced. Many balloon pilots operateto collapse the balloon after landing.
their envelopes at temperatures significantlyAn older, and today less commonly used, style of
below the maximum in order to extend thevent is called a "Velcro-style" vent. This too is a
longevity of their envelope fabric.disk of fabric at the top of the balloon. However,
For typical atmospheric conditions, a hot air balloonrather than having a set of "vent lines" that can
requires about 3 cubic meters of enveloperepeatedly open and close the vent, the vent is
volume in order to lift 1 kilogram (50 ft3/lb). Thesecured by "hook and loop" fasteners (such as
precise amount of lift provided depends not onlyVelcro) and is only opened at the end of the flight.
upon the internal temperature mentioned above,Balloons equipped with a "Velcro-style" vent
but the external temperature, altitude above seatypically have a second "maneuvering vent" built
level, and humidity of the surrounding air. On a hotinto the side (as opposed to the top) of the
day, the balloon cannot be loaded as much as onballoon.
a cool day, because the temperature required forSome hot air balloons have turning vents which
launch will exceed the maximum sustainable forare side vents which, when opened, cause the
nylon envelope fabric.balloon to rotate. Such vents are particularly useful
In the lower atmosphere, the lift provided by afor balloons with rectangular baskets in order to
hot air balloon decreases about 3% for eachalign the wider side of the basket for landing.