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Article #2: How are hot air baloons made

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A hot air balloon for manned flight uses about 3% for each 1,000 meters (1% per
a single layered, fabric gas bag (lifting 1,000 ft) of altitude gained.
"envelope"), with an opening at the A range of envelope sizes is available.
bottom called the mouth. Attached to the The smallest, one-person, basket-less
envelope is a basket, or gondola, for balloons (called "Hoppers" or
carrying the passengers. Mounted above "Cloudhoppers") have less than 1,000
the basket and centered in the mouth is cubic meters (35,000 ft3) of envelope
the "burner" which injects a flame into volume. At the other end of the scale are
the envelope, heating the air within. the balloons used by large commercial
Raising the air temperature inside the sightseeing operations that carry well
envelope makes it lighter than the over two dozen people and have envelope
surrounding (ambient) air. This causes volumes of up to 15,000 cubic meters
the balloon and its payload to rise. (600,000 ft3). However, most balloons are
Modern hot air balloons are usually made roughly 2,500 cubic meters (100,000 ft3)
of synthetic fabrics such as ripstop and carry 3 to 4 people.
nylon, a light weight fabric of high The Rozier type of hybrid balloon, called
strength. During the manufacturing after its creator, Jean-Francois Pilatre
process, the material is cut into panels de Rozier, has separate cell for helium
and sewn together, along with structural as well as a cone below for hot air (as
load tapes (webbing) that carry the is used in a hot air balloon) to heat the
weight of the gondola or basket. The helium at night.
heater or burner is fueled by propane, a The direction of flight depends on the
liquefied gas stored in pressure vessels, wind, but the altitude of the balloon can
similar to high pressure forklift be controlled by changing the temperature
cylinders. of the air inside the envelope.
The amount of lift (or buoyancy) provided The top of the balloon usually has a vent
by a hot air balloon depends primarily of some sort. The most common type of
upon the difference between the vent is a disk-shaped flap of fabric
temperature of the air inside the called a parachute vent. The fabric is
envelope and the temperature of the air connected around its edge to a set of
outside the envelope. For most envelopes "vent lines" that converge in the center.
made of nylon fabric, the maximum (The arrangement of fabric and lines
internal temperature is limited to looks roughly like a parachute -- thus
approximately 120 °C (250 °F). It the name.) These "vent lines" are
should be noted that the melting point of themselves connected to a control line
nylon is significantly higher than these that runs to the basket. A parachute vent
maximum operating temperature -- about is opened by pulling on the control line.
230 °C (450 °F). However the lower Once the control line is released, the
temperatures are generally used because pressure of the remaining hot air pushes
the higher the temperature, the more the vent fabric back into place. A
quickly the strength of the nylon fabric parachute vent can be opened briefly
degrades over time. With a maximum while in flight to initiate a rapid
operating temperature of 120 °C, balloon descent. (Slower descents are initiated
envelopes can generally be flown for by allowing the air in the balloon to
between 400 and 500 hours before the cool naturally.) The vent is pulled
fabric needs to be replaced. Many balloon completely open to collapse the balloon
pilots operate their envelopes at after landing.
temperatures significantly below the An older, and today less commonly used,
maximum in order to extend the longevity style of vent is called a "Velcro-style"
of their envelope fabric. vent. This too is a disk of fabric at the
For typical atmospheric conditions, a hot top of the balloon. However, rather than
air balloon requires about 3 cubic meters having a set of "vent lines" that can
of envelope volume in order to lift 1 repeatedly open and close the vent, the
kilogram (50 ft3/lb). The precise amount vent is secured by "hook and loop"
of lift provided depends not only upon fasteners (such as Velcro) and is only
the internal temperature mentioned above, opened at the end of the flight. Balloons
but the external temperature, altitude equipped with a "Velcro-style" vent
above sea level, and humidity of the typically have a second "maneuvering
surrounding air. On a hot day, the vent" built into the side (as opposed to
balloon cannot be loaded as much as on a the top) of the balloon.
cool day, because the temperature Some hot air balloons have turning vents
required for launch will exceed the which are side vents which, when opened,
maximum sustainable for nylon envelope cause the balloon to rotate. Such vents
fabric. are particularly useful for balloons with
In the lower atmosphere, the lift rectangular baskets in order to align the
provided by a hot air balloon decreases wider side of the basket for landing.






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