Patent Application
20110101001
1. Technical Field
Embodiments of the present invention include a tank assembly for storing a compressed gas. The tank assembly includes a collar assembled thereto to facilitate the mounting of bodies to the tank assembly.
2. Background Art
Tanks for storing compressed gas are well known. Conventional tanks are capable of storing compressed gas at very high pressures. For example, hydrogen may be stored in tank assemblies at pressures of up to 10,000 psi, and beyond. However, the systems that use compressed gases, such as an internal combustion engine and fuel cells, typically operate at far lower pressures. Accordingly, the compressed gas stored in the tank assembly must first pass through a regulator or some other mechanism which reduces the pressure of the stored gas before it can be utilized. Conventional tank assemblies do not include a mount for regulators. Accordingly, systems utilizing a conventional tank assembly position the regulator remotely from the valve. Positioning the regulator remotely from the valve has many disadvantages including, but not limited to, the added cost associated with using a high pressure hose/line to contain the high pressure compressed gas outside of the tank assembly prior to passing through the regulator. Additionally, the wear and tear associated with maintaining a high pressure compressed gas in a hose/line is greater than the wear and tear associated with maintaining gas at lower pressures. These and other disadvantages increase as the distance between the regulator and the tank assembly's valve increases.
Prior solutions to this problem have involved mounting devices such as regulators directly to the valve of the tank assembly. Such devices, however, frequently have a good deal of mass. The valve of a tank assembly may not be sufficiently robust to tolerate the forces acting on the valve and the devices during normal equipment operations.
Various embodiments of a tank assembly are disclosed herein. In a first embodiment, the tank assembly comprises the gas impermeable liner having a neck having a threaded bore. An annular collar having a generally circular opening is disposed around the neck. A structural layer substantially envelopes the liner and secures the annular collar to the neck.
In an implementation of the first embodiment, the annular collar includes a raised annular flange. In a variation of this implementation, the raised annular flange defines a plurality of mounting bores. In a further variation, the plurality of mounting bores are threaded.
In another implementation of the first embodiment, the annular collar includes a generally circular channel defined in a surface of the collar. The channel is generally concentric with the generally circular opening of the annular collar. In a variation of this implementation, the annular collar further includes a raised annular flange disposed concentrically with the channel. In a further variation, the raised annular flange has a smaller diameter than the channel. In a further variation, the raised annular flange defines a plurality of threaded mounting bores disposed about the raised annular flange.
In another implementation of the first embodiment, the liner comprises metal.
In a second embodiment, a tank assembly comprises a gas impermeable liner having a neck. An annular collar having a generally circular opening, a first surface, and an annular flange protruding above the first surface and disposed generally concentrically with the opening, is disposed around the neck such that the first surface is substantially coplanar with an upper surface of the neck. A structural layer substantially envelopes the liner and secures the collar to the neck.
In an implementation of the second embodiment, a surface of the annular collar defines a generally circular channel disposed generally concentrically with the opening. The channel has a larger diameter than a diameter of the annular flange.
In another implementation of the second embodiment, the annular flange defines mounting bores. In a variation of this implementation, the mounting bores are disposed about the annular flange such that each mounting bore is substantially equidistant from each adjacent mounting bore. In another variation, a surface of the annular collar defines a generally circular channel disposed generally concentrically with the opening. The channel has a larger diameter than a diameter of the annular flange. In another variation, the mounting bores are threaded.
In a third embodiment, a tank assembly comprises a gas impermeable liner having a neck that defines a passage. An annular collar having a generally circular collar opening and a raised annular flange disposed generally concentrically with the collar opening is disposed around the neck such that the neck is received in the collar opening. This third embodiment also includes an annular mounting bracket having a generally circular bracket opening. The mounting bracket is rotatably mounted on the collar such that the bracket opening engages the raised annular flange of the annular collar. This third embodiment also includes a structural layer substantially enveloping the liner and securing the collar to the neck.
In an implementation of this third embodiment, the raised annular flange defines a plurality of mounting bores. The tank assembly further comprises a plurality of fasteners, each fastener being secured within a respective one of the mounting bores. The plurality of fasteners are configured to inhibit rotation of the mounting bracket with respect to the raised annular collar. In a variation of this implementation, the raised annular collar defines a substantially circular channel that is disposed substantially concentrically with the collar opening. The channel has a larger diameter than a diameter of the flange. The tank assembly further comprises a sealing member that is disposed within the channel. A bottom surface of the annular mounting bracket engages the sealing member. The bottom surface of the mounting bracket and the sealing member cooperate to provide a gas-tight fit between the annular mounting bracket and an annular collar when the plurality of fasteners engage the mounting bores. In a variation of this implementation, the plurality of mounting bores are threaded, the plurality of fasteners are threaded fasteners that are in threaded engagement with the plurality of mounting bores. In another variation, the sealing member comprises an O-ring.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and in which:
Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily drawn to scale, some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for the claims and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.
In view of the high pressures at which compressed gases such as hydrogen may be maintained, it may be desirable to reduce the pressure of such compressed gas after the compressed gas has been discharged from the tank assembly in which it is stored. This condition may be accomplished by mounting a regulator close to the outlet/valve of the tank assembly. Mounting the regulator in close proximity to the outlet may eliminate the need for extensive high pressure lines/hoses. Such a mounting condition may reduce leakage from the fuel containment system as well as reduce the cost associated with providing high pressure line/hose.
A conventional tank assembly is configured to receive and store high pressure compressed hydrogen or other gases at pressures up to and exceeding 10,000 psi include a gas impermeable liner made from materials including, but not limited to, plastics, or metal. The liner is enveloped/encased within an outer structural layer that provides the strength to contain the high pressure compressed gas and prevent the liner from rupturing. Conventionally, the structural layer comprises a composite material such as, but not limited to, carbon fiber.
The liner has a neck portion having a diameter that is smaller than a diameter of the remainder of the liner. A valve is mounted to the neck, in some cases through threaded engagement between threads formed on an internal wall of the neck and threads formed on an outer wall of the valve. This arrangement permits the valve to be screwed into position in a bore formed by an internal wall of the neck.
In accordance with the embodiments of the present invention, an annular or ring-like collar is positioned around the neck of the liner prior to, or during, the application of the composite material to the liner. An underside of the collar includes a channel to receive and engage with the strands of the composite material. The liner, collar, and composite material is then heated until the composite material and/or an epoxy resin on the composite material cures, forming a robust casing around the liner and collar.
The collar is further configured to permit attachment of a mounting bracket to the collar. The mounting bracket is configured to receive and retain a regulator or any other device. The mounting bracket is further configured to move with respect to the collar to permit adjustment of the angle and proximity of the regulator with respect to the outlet of the valve of the tank assembly to permit proper alignment and close proximity between the regulator and the valve. In other embodiments, the collar may be placed elsewhere on the liner to permit the mounting of bodies/apparatuses to any desirable portion of the tank assembly.
A greater understanding of the embodiments of the invention disclosed herein may be obtained through a review of the detailed description below as well as a review of the illustrations accompanying this application.
With respect to
Tank assembly 20 includes a liner 22. Liner 22 is a gas impermeable container for containing the compressed gas. Liner 22 may be made of any gas impermeable material including, but not limited to, metal, or plastic. In at least one embodiment, liner 22 may comprise aluminum.
Liner 22 includes a neck 24. Neck 24 has a smaller diameter than the remainder of liner 22 and serves as a pathway for gasses to enter and exit to and from liner 22. Neck 24 defines a central bore and is threaded along an internal wall. The threads of neck 24 are configured to engage corresponding threads defined in an outer surface of a valve 26. The valve 26 generally controls the flow of the gas from the liner 22. While
An annular collar 28 is positioned adjacent an external wall of neck 24. In the illustrated embodiment, annular collar 28 is ring-like structure and defines an internal annular collar bore 30. Annular collar 28 includes a first surface 32 which is substantially flush with an upper surface of neck 24. In other embodiments, the first surface 32 may be disposed above or below an upper surface of neck 24 without departing from the teachings of the present invention.
Annular collar 28 further includes a raised flange 34 adjacent first surface 32 and protruding above first surface 32. Raised flange 34 is generally circular and is generally concentric with internal annular collar bore 30. Raised flange 34 includes a plurality of mounting bores 36 defined in an upper surface thereof. In the illustrated embodiment, mounting bores 36 are threaded and are configured to receive threaded fasteners, discussed below. In other embodiments, a greater or lesser number of mounting bores 36 may be employed without departing from the teachings of the present invention. In still other embodiments, mounting bores 36 may not be threaded.
Annular collar 28 further includes a channel 38 defined in a second surface 40. Channel 38 extends around annular collar 28 in a generally circular configuration and is generally concentric with internal annular collar bore 30 and raised flange 34. In other embodiments, channel 38 may be non-circular and/or non-concentric with raised flange 34 or with internal annular collar bore 30 without departing from the teachings of the present invention. Channel 38 is configured to receive a sealing member 42 (see
Annular collar 28 further includes a retaining channel 44 defined in an underside of annular collar 28. Retaining channel 44 is configured to engage structural layer 46 (as discussed below) and to cooperate with structural layer 46 to retain annular collar 28 in a substantially stationary position with respect to neck 24. Retaining channel 44 generally resembles the letter J in cross-section. In other embodiments, retaining channel 44 may have any other shape or configuration that is conducive to engagement with structural layer 46 and retention of annular collar 28 on neck 24. In the illustrated embodiment, retaining channel 44 extends in circular fashion around an entire underside of annular collar 28. In other embodiments, retaining channel 44 may comprise a plurality of channel segments disposed intermittently around an underside of annular collar 28.
Tank assembly 20 further includes structural layer 46. As illustrated in
In some embodiments, structural layer 46 may be wrapped around liner 22 by a manufacturing process wherein liner 22 is turned as strands of composite material are wrapped or draped around liner 22. As the strands of carbon fiber are wrapped around the outer portion of neck 24, they enter and engage with retaining channel 44. The wrapping of liner 22 with carbon fiber strands continues until structural layer 46 has reached a desired level of thickness. The greater the pressure of the compressed gas, the thicker will be structural layer 46. Once the desired thickness has been achieved, the tank assembly 20, including the wound strands of structural layer 46, are heated. This causes the carbon fiber strands of structural layer 46 and/or an epoxy or other resin applied thereto to melt and/or bond to form a generally unified, monolithic structure.
Once structural layer 46 is assembled and cured, the only portion of liner 22 that is visible from outside tank assembly 20 is an upper surface of liner 22. Similarly, only an upper portion of annular collar 28 is visible from outside tank assembly 20. The underside, and in particular, retaining channel 44 are hidden from view.
As illustrated
With respect to
As illustrated, threaded fasteners 54 include a head portion 56 and a threaded portion 58 (see
With respect to
When tank assembly 20 is mounted in the trunk or cargo portion of a vehicle, there is a risk that the compressed gas may leak out of tank assembly 20 and enter the passenger compartment of the vehicle. The manufacturer is required to provide an airtight “vent box” (or enclosure as noted above) to direct such leaked gas to an area outside of the passenger compartment. By providing a sealing member 42 between annular mounting bracket 48 and annular collar 28, an airtight seal is provided that prevents gas from passing between annular collar 28 and annular mounting bracket 48. This permits a manufacturer to design and install the vent box that can attach to annular mounting bracket 48 instead of one which needs to be attached directly to annular collar 28. Various mounting holes as shown on the annular mounting bracket 48 facilitate coupling the vent box thereon. This arrangement can afford a manufacturer greater flexibility when designing the vent box.
With respect to
As illustrated in
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
