Modular fuel storage system

Methods and systems for modular fuel storage and transportation are provided. In an embodiment, a fuel storage system includes one or more fuel containers each supported by a fuel container support assembly. The fuel storage system may be mounted to a transportation device such as a vehicle or used in a stand-alone fashion. Each support assembly may include a plurality of detachable end support members such as end support members configured to support the end portions of the fuel container and side support members configured to support the body portion of the fuel container. Some of the end support members may include neck grooves such that when the end support members are coupled, the neck grooves form an enclosure around the neck portion of the fuel container. In an embodiment, the support assembly is configured to facilitate release of excess pressure in the fuel container.

BACKGROUND OF THE INVENTION

Fuel storage systems including fuel containers and support structures thereof are generally used to store and/or transport fuels such as natural gas. Typically, such fuel storage systems are custom built and/or hard to assemble and/or dissemble, making it difficult to change the configuration of or mix and match components of such systems. Thus, a need exists for improved systems and methods of supporting and/or storing fuel. A further need exists for modular fuel storage that may accommodate various configurations.

SUMMARY OF THE INVENTION

Methods and systems for modular fuel storage and transportation are provided. In an embodiment, a fuel storage system includes one or more fuel containers each supported by a fuel container support assembly. The fuel storage system may be mounted to a transportation device such as a vehicle or used in a stand-alone fashion. Each support assembly may include a plurality of detachable end support members such as end support members configured to support the end portions of the fuel container and side support members configured to support and/or connect the end support members. Some of the end support members may include neck grooves such that when the end support members are coupled, the neck grooves form an enclosure around the neck portion of the fuel container. In an embodiment, the support assembly is configured to facilitate release of excess pressure in the fuel container.

According to an aspect of the present invention, a fuel container support assembly for supporting a fuel container. The fuel container support assembly comprises an end frame comprising a first end support member and a second end support member that are detachably coupled to provide support for a neck portion of the fuel container; and a plurality of side support members detachably coupled to the end frame to protect a body portion of the fuel container.

In some embodiments, at least one of the side support members can be detachably coupled to both the first end support member and the second end support member. The first end support member and the second end support member can be interchangeable. Similarly, the plurality of side support members can be interchangeable.

In some embodiments, the first end support member and the second end support member each comprises a neck groove such that when the first end support member is coupled to the second end support member, the respective neck grooves form an enclosure around the neck portion of the fuel container. The first end support member and the second end support member can be coupled via a fastener. The fastener can include a wedge or a bolt.

In some embodiments, the first end support member can include an opening that is configured to facilitate release of excess pressure from the fuel container.

In some embodiments, the fuel container support assembly can further include a second end frame comprising a third end support member and a fourth end support member that are detachably coupled to provide support for a bottom portion of the fuel container.

In some embodiments, the fuel container support assembly can further include a trailing edge fairing usable for reducing drag caused by wind, the trailing edge fairing detachably coupled to at least one of the first end support member or the second end support member.

According to another aspect of the present invention, a fuel storage system is provided. the fuel storage system comprises one or more fuel container support assemblies, each configured to support a fuel container and comprising one or more openings configured to allow release of excess pressure from the fuel container, the one or more fuel container support assemblies arranged such that the openings for the one or more fuel container support assemblies form a channel for releasing excess pressure from the corresponding fuel containers supported by the one or more fuel container support assemblies.

In some embodiments, each of the one or more fuel container support assemblies comprises an end frame comprising a first end support member and a second end support member that are detachably coupled to provide support for a neck portion of a fuel container and a plurality of side support members detachably coupled to the end frame to protect a body portion of the fuel container. At least some of the one or more fuel containers support assemblies can be configured to be coupled to another fuel container support assembly. The first end support member and the second end support member can be interchangeable. Similarly, the plurality of side support members can be interchangeable. In some embodiments, the first end support member and the second end support member can be detachably coupled via a groove and a wedge.

According to another aspect of the present invention, a method for supporting a fuel container is provided. The method comprises providing a partially-assembled support assembly comprising a first end support member configured to support a neck portion of the fuel container and one or more side support members detachably coupled to the first end support member, the one or more side support members being configured to protect a body portion of the fuel container; loading the fuel container onto the partially-assembled support assembly such that the neck portion of the fuel container is supported by the first end support member and the body portion of the fuel container is substantially enclosed by the one or more side support members; and attaching a second end support member to the partially-assembled support assembly such that the neck portion of the fuel container is substantially enclosed by the first end support member and the second end support member.

In some embodiments, attaching the second end support member can include coupling the second end support member to the first end support member. Attaching the second end support member can further comprise coupling the second end support member to at least one of the one or more side support members. The method can further comprise attaching a collar to the neck portion of the fuel container prior to loading the fuel container onto the support assembly.

INCORPORATION BY REFERENCE

DETAILED DESCRIPTION OF THE INVENTION

The invention provides systems and methods for storing and/or transporting fuels in accordance with aspects of the invention. Various aspects of the invention described herein may be applied to any of the particular applications set forth below or for any other types of tank attachment systems. The invention may be applied as a standalone system or method, or as part of a system (such as a vehicle) that utilizes fuel. It shall be understood that different aspects of the invention can be appreciated individually, collectively, or in combination with each other.

FIGS. 1a-dillustrate exemplary ways a fuel storage system102may be attached and/or mounted to a vehicle104. In various embodiments, a vehicle104may refer to any mobile machine or device designed or used to transport passengers or cargos. Examples of a vehicle may include bikes, cars, trucks, buses, motorcycles, trains, ships, boats, aircrafts and the like. A truck may include a light duty truck (e.g., class 1, class 2 or class 3), medium duty truck (e.g., class 4, class 5 or class 6), or heavy duty truck (e.g., class 7 or class 8). In some embodiments, the vehicles may be cars, wagons, vans, buses, high-occupancy vehicles, dump trucks, tractor trailer trucks, or any other vehicles. While a vehicle is illustrated herein, any other live or inanimate object or system (e.g., a building, a person, an animal, and a robot) may be attached to the fuel storage system discussed herein in any suitable manner including but not limited to the examples discussed herein.

In some embodiments, a fuel storage system102may be configured to support one or more fuel containers or vessels with the same or different characteristics. The fuel containers may be of any size, capacity, shape and/or weight and may be made of any suitable material. For example, the fuel containers may have a shape that is substantially cylindrical, rectangular, spherical, or the like. In addition, the fuel container(s) may be used to store any type(s) of fuel such as solid (e.g., coal), liquid (e.g., diesel) or gaseous fuels (e.g., natural gas). For example, gaseous fuels may include hydrogen or hydrogen based gas, hythane, H2CNG, or any other gas.

In some embodiments, a fuel container may be configured to store fuel at or above a certain amount of pressure and/or at or below a certain temperature. For example, the fuel container may be configured to store liquefied natural gas (LNG) at or below a predetermined temperature (e.g., −260 F) or compressed natural gas (CNG) at or above a predetermined pressure (e.g., 3,600 psi). In some embodiments, the fuel containers may be constructed according standards promulgated by organizations such as the International Organization for Standardization (ISO).

As illustrated byFIGS. 1a-d, a fuel storage system102may be mounted or attached to any suitable portion(s) of a vehicle104. In an embodiment, such as illustrated inFIG. 1a(showing a side view of the vehicle104), the fuel storage system102may be mounted behind a cab of the vehicle104, for example, on the frame rail of the vehicle104. In another embodiment, such as illustrated inFIG. 1b(showing a top view of the vehicle), the fuel storage system102may be mounted on one or both sides of the vehicle104. In another embodiment, such as illustrated inFIG. 1c(showing a side view of the vehicle104), the fuel storage system102may be mounted on the top of the vehicle104, for example, on or in the roof of the vehicle. In yet another embodiment, such as illustrated inFIG. 1d(showing a side view of the vehicle104), the fuel storage system102may be mounted on a trailer or a detachable portion of a vehicle104. In other embodiments, a fuel storage system may be mounted to a vehicle using a combination of the illustrated methods. Variations of above-described embodiments are also within the scope of the invention. For example, the fuel storage system may be installed in the front or back of the body of a vehicle. In various embodiments, the location and/or manner of attachment of the fuel storage system to the vehicle may be based on a variety of factor including the capacity and type of the fuel containers, type of the vehicle, business requirement, and the like.

In some embodiments, at least some of the fuel stored in the fuel storage system102may be used to power and/or propel the vehicle104that carries the fuel storage system102. The fuel may be a gaseous fuel, such as natural gas. The fuel may be contained within a gaseous fuel containing device, such as a tank, vessel, or any other type of device capable of containing a gaseous fuel. Any description herein of a fuel tank, vessel, or any other type of gaseous fuel containing device may be applicable to any other type of gaseous fuel containing device. The gaseous fuel containing device may be capable of containing a fuel with a certain amount of pressure. For example, the gaseous fuel containing device may be capable of containing a fuel having less than or equal to about 10000 psi, 8000 psi, 7000 psi, 6500 psi, 6000 psi, 5500 psi, 5000 psi, 4750 psi, 4500 psi, 4250 psi, 4000 psi, 3750 psi, 3500 psi, 3250 psi, 3000 psi, 2750 psi, 2500 psi, 2000 psi, 1500 psi, 1000 psi, 500 psi, 300 psi, 100 psi, or less.

In other embodiments, none of the fuel stored in the fuel storage system102is actually used to power the vehicle104. Such may be the case for a mobile fuel station (similar to that illustrated byFIG. 1d) that is used to provide fuel in contingency or emergency situations.

In some embodiments, the fuel storage system may include one or more modular fuel container support assemblies (hereinafter support modules or support assemblies) used to support and/or secure fuel containers such as described above. In a typical case, a support assembly is configured to support only one fuel container. Alternatively, a support assembly may be used to support more than one fuel containers. Such support assemblies may be used to stabilize, support or otherwise protect the fuel containers from damage caused by movement (such as during transit), external impact, natural elements, erosion, and the like.

In various embodiments, a fuel storage system described herein may include an arbitrary number of support assemblies and the support assemblies of the fuel storage system may be arranged according to different configurations to accommodate different requirement or circumstances, such as storage space dimensions, weight restrictions, and the like. For example, the configuration of the support assemblies may be customized to fit a particular storage space (e.g., on a vehicle, in a warehouse). As another example, the support assemblies of the fuel storage system may be detachably coupled to each other or separately located.

FIGS. 2a-dillustrate exemplary ways support assemblies of a fuel storage system may be configured. In the examples, each rectangle prism202is used to represent a support assembly that is configured to support a fuel container therein. While the support assemblies discussed herein are illustrated as rectangular prisms, it is understood that, in various embodiments, the support assemblies may take on any suitable shapes such as cylinder, spheroid, triangular prism, and the like. In some embodiments, the support assemblies are shaped to improve spatial efficiency, weight, cost, and the like, of the overall fuel storage system. For example, support assemblies shaped like rectangular prisms can be easily stacked or placed adjacent to each other, thereby providing spatial efficiency. In an embodiment, such as illustrated inFIG. 2a, the support assemblies202may be stacked on top of each other along one of the four side surfaces in a substantially vertical fashion. In another embodiment, such as illustrated inFIG. 2b, support assemblies202may be arranged along one of the four side surfaces in a substantially horizontal fashion. In another embodiment, such as illustrated inFIG. 2c, support assemblies202may be arranged along one of the two end surfaces in a substantially horizontal fashion. In yet another embodiment, such as illustrated inFIG. 2d, support assemblies202may be arranged along one of the two end surfaces in a substantially vertical fashion. In other embodiments, the support assemblies202may be arranged using a combination of the illustrated methods or using any other suitable methods. For example, the support assemblies202may be arranged in two-dimensional or three-dimensional arrays or to form other regular or irregular shapes. Advantageously, the structure of the support assemblies described herein allows the support assemblies to be arranged into arbitrary configurations to accommodate any particular requirement or limitation (e.g., space restriction).

In various embodiments, support assemblies202such as illustrated inFIGS. 2a-dmay or may not be coupled (e.g., detachably or permanently) to the other support assemblies to form a configuration. In some embodiments, two support assemblies may be coupled or affixed to each other using one or more fasteners. The fasteners may be an inherent part of support assemblies (e.g., tongue and groove, wedge and slide, joints and the like) or external to the support members (e.g., wires, locks, glue, welding, and the like). Exemplary means of fastening two or more support assemblies may include nuts and bolts, nails, locks, latches, wires, joints, soldering, welding, gluing and the like. In other embodiments, the support assemblies may simply be placed or stacked adjacent to one another without any fastening mechanism.

A fuel storage module may or may not share component(s) with adjacent module(s). Any means of fastening may be used to couple two fuel storage modules such as using nuts and bolts, nails, locks, latches, wires, grooves and slides and the like.

FIG. 3illustrates an exemplary fuel storage system300, in accordance with an embodiment. The fuel storage system300comprises three support assemblies301,302and303. In other embodiments, the fuel storage system may include more or less than three support assemblies. As discussed above, support assemblies may be stacked or otherwise arranged to improve spatial efficiency. In this example, three support assemblies301,302and303are stacked on top of each other in a configuration similar to that illustrated inFIG. 2a. In other embodiments, the support assemblies may be arranged in other suitable configurations.

In the illustrated embodiment, each support assembly includes two opposing end frames and a plurality of (e.g., two) side frames. An end frame may be used to protect a portion at or near an end of a fuel container supported by the support assembly. The end frame may comprise a single end support member or two or more detachably-coupled end support members such as304and306or308and310. The end frame may provide support for the distal portions of the fuel containers supported by the support assemblies. In an embodiment, the end support members may be configured to interface with a portion of the fuel container. For example, end support members304and306, when coupled, may form an enclosure305shaped to interface with a top or neck portion of the fuel container. For another example, end support members308and310may be coupled to provide support for a bottom portion of fuel container.

The two end frames of a support assembly may be identical or different. In some embodiments, one of the end frames may be configured to support or interface with a particular end (e.g., top) of a fuel container while the other end frame is may be configured to support or interface with the opposite end (e.g., bottom) of the fuel container. Thus, the two end frames may be different. For example, the top end frame may include an opening for supporting the neck of the fuel container while the bottom end frame may not have such an opening. Thus, the end support members for the bottom portion of the fuel container may not be configured to provide support for the top portion of the fuel container. In some other embodiments, the two end frames may be substantially similar, such as illustrated inFIG. 3. For example, the end support members308and310may be substantially the same as end support members304and306, respectively. In such cases, both end frames may be configured to support or interface with both the top and the bottom of a fuel container. For example, in some cases, both the top portion and the end portion of the fuel container may have neck portions that are supported by the end support members of the end frames. In some instances, the two end frames of the support assembly and the components thereof may be interchangeable, thereby lowering the cost of manufacturing and/or assembly of the fuel module.

In some cases, an end frame may include only one single end support member instead of two coupled end support members to provide support to a top or bottom portion of a fuel container. Such a single support member may or may not resemble the structure formed by the coupled end support members discussed above. For example, the single end support member may or may not include an enclosure similar to the enclosure305to interface with a top portion of the fuel container.

In some cases, an end frame may include more than two end support members that are detachably coupled to support a top and/or bottom portion of a fuel container. For example, in an embodiment, four end support members may be coupled to form an end frame similar to the enclosure305illustrated inFIG. 3. In an embodiment, the end frames described herein are configured to support the weight of a fuel container supported therein. In an embodiment, two or more end support members of an end frame may have similar shapes and/or substantially symmetric along an interface where the two or more end support members are coupled. For example, two end support members304and306have substantially the same shapes and are substantially mirror-images of each other along the interface where the end support members are coupled. As discussed above, having such interchangeable and/or identical end support members can help lower the cost of manufacturing and/or assembly.

A support assembly can further include a plurality of side support members to prevent or reduce movement or damage to the body or sides of a fuel container supported therein. As used herein, the term “side support member” is used to refer to the component of the support assembly that protects one side (but not the top or bottom) of a fuel container. In one embodiment, the side support member may be formed by a single-piece surface structure. In other embodiments, such as illustrated inFIG. 3, a side support may be formed by a top side frame (e.g., side frame316) and a bottom side frame (e.g., side frame318) with zero or more truss members320in between. Such a structure can help reduce the weight of the side support member.

A support member can includes a plurality of side frames such as312and314or316and318. In some embodiments, the planes formed by the side frames may be substantially parallel to each other. For example, the plane formed by side frames312and314may be substantially parallel to the plane formed by side frames316and318. In other cases, the planes formed by the side frames may intersect each other, for example, in a “v” manner.

In an embodiment, one, two, three or more side support members may be used to connect and/or secure the two end frames such as described above. For example, in an embodiment, a support assembly may comprise two side support members each formed by a top side frame and a bottom side frame with zero or more truss members in between may be coupled to and all four end support members of a support assembly such as illustrated inFIG. 3. In another embodiment, a support assembly may comprise only one side support member that may be coupled to all four end support members. In yet another embodiment, a support assembly may include four side support members each connecting the two end frames.

A side frame may be configured to couple with an end frame at each end of the side frame. Thus, the two ends of the side frame may be coupled to two opposite facing end frames. Where the end frame comprises one or more end support members, one end of the side frame may be configured to couple with at least one end support members. For example, side frame312is coupled at one end to end support member304and at another end to end support member310. In various embodiments, a side frame may be coupled to an end support member in any suitable manner such as via a fastener (e.g., bolt) or being plugged directly into a socket or opening provided by the corresponding end frame or end support member. In some cases, the side frame may be easily attached to and/or detached from an end frame to lower the cost of associated with assembly and/or dissembling of the support assembly.

As discussed above, a side support member may be formed by a top side frame (e.g., side frame316) and a bottom side frame (e.g., side frame318) with zero or more truss members320in between. The truss members320may include one or more slanted bars such as shown inFIG. 3. In other embodiments, the truss member320may include other patterns. The truss members may be permanently attached (e.g., welded or soldered) or detachably attached to the side frames. In general, the design of the side frames and/or the truss members between the side frames may be based on a variety of factors such as dimensions and/or capacity of the fuel container supported thereby, material used to construct the side frames and/or truss members, strength-to-weight ratio requirement, location or position of the support assemblies in a configuration, aesthetic reasons and the like. In various embodiments, some or all of the components of the side support member (e.g., side frames) may be interchangeable to easy the manufacturing, assembly, and/or disassembly of the support assembly.

In various embodiments, a support assembly may comprise any number of attachable and/or detachable components or members. For example, in an embodiment, a support assembly may include four components including two single-piece end frames and two side supports that connect the two end frames. In another embodiment, such as illustrated inFIG. 3, a support assembly may include six components including two pairs of end support members where each pair may be coupled to form an end frame and two side supports, each of which may be used to hold together all four of the end support members. In yet another embodiment, a support assembly may include eight components including two pairs of end support members described above and four side frames, each side frame used to connect two opposite-facing end support members.

In various embodiments, a support assembly may comprise any number of distinctly shaped components. For example, in an embodiment, a support assembly may require only two distinctly shaped components, one for an end support, one of a side support. In such an embodiment, two or more identical end support members may be coupled to form an end frame and one or more identical side supports may be used to connect the end frames. By reducing the number of distinct parts and increasing the number of interchangeable parts of a support assembly, the techniques described herein advantageously eases the task of manufacturing, assembly, and/or disassembly of such support assemblies. For example, such an approach may lower the cost of manufacturing by reducing the number of distinct pieces to manufacture and/or lower the cost of assembly by reducing the risk of assembly error. In other embodiments, a support assembly may require more than two distinctly shaped components. For example, the end support members for the top of the fuel container may be different from the end support members for the bottom of the fuel container. For another example, the side supports for the support assembly may be of different shapes. The particular number of components and/or shapes of the components may be determined by cost, fuel container type, fuel type, vehicle type, mounting environment and/or other considerations.

In some embodiments, the side frames may be designed to hold a fuel container in one or more orientations. For example, in an embodiment, the distance between one pair of side frames (e.g., side frames312and318) may be less than the distance between another pair of side frames (e.g., side frames314and316) so as to support a fuel container in a substantially horizontal manner (e.g., with the narrow pair of side frames312and318at the bottom and the wider pair of side frames314and316at the top). In another embodiment, the distance between one pair of side frames may be substantially similar to the distance between another pair of side frames so as to support fuel containers held either substantially vertically or horizontally.

In some instances, the support assemblies located toward the bottom of a stack of support assemblies (e.g., support assembly303inFIG. 3) may be designed to be more durable or capable of withholding more impact than the support assemblies located toward the top of the stack (e.g., support assembly301inFIG. 3). For example, as illustrated inFIG. 3, the truss members between side frames for the bottommost support assembly303may be configured to withhold more impact than the truss members for the support assemblies on top of it (e.g., support assemblies301and302) making it sturdier than the other of the support assemblies laid on top of it. In contrast, minimal truss members may be supported for the topmost support assembly301. In some embodiments, the body portion of a fuel tank at least partially enclosed by the planes formed by the side frames of a fuel container support assembly. In general, various support assemblies with the same or different characteristics may be mixed-and-matched to suit the need of particular configurations of the support assemblies.

In various embodiments, components or portions of a support assembly described herein (e.g., end support members, side frames, truss members, side support) may be constructed using any suitable material or combination of materials. For example, the materials used may include metal such as steel, iron, aluminum, titanium, copper, brass, nickel, silver and the like or any alloys or combinations thereof. The materials may also include a polymer or a composite material, such as carbon fiber, or fiberglass. The choice and amount of materials used may be based on various factors including cost, strength-to-weight ratios, location or position of the support assemblies in a configuration, aesthetic reasons and the like. In some instances, the support assemblies located toward the bottom of a stack of support assemblies (e.g., support assembly303inFIG. 3) may be designed with a more durable and/or heavier material than the material used for the support assemblies located toward the top of the stack (e.g., support assembly301inFIG. 3). In various embodiments, the dimensions of components or portions of a support assembly described herein (e.g., end support members, side frames) may be based at least in part on the characteristics of fuel containers (e.g., dimensions, capacities, type of fuel) supported therein, space considerations for the support assemblies, and the like.

A uniform interface for connection may be provided between components of a support assembly to lower the cost of manufacturing, assembly, and/or disassembly of the support assembly. As such, during assembly of a support assembly, the components may be mixed-and-matched. For example, in an embodiment, different components of the support assembly may be connected using a LEGO-like interface For example, the interface for coupling a side frame and an end support member may be the same between any side frame and end support member. Besides facilitating connection between internal components of a support assembly, such uniform interface may allow one support assembly to be coupled externally to another support assembly. For example, as shown inFIG. 3, support assemblies301,302and303are stacked vertically along their side support members or side frames. The side support members and/or end frames may provide fastening mechanisms for affixing two adjacent support assemblies. Thus, the end support members may be coupled or connected without the use of additional hardware. Additionally, adjacent support assemblies may be coupled by external fasteners such as nuts and bolts to better secure the support assemblies. For instance, such fasteners may be used to couple end support members304and322and/or to couple end support members310and324. In yet other embodiments, the support assemblies may be arranged (e.g., stacked or placed adjacent to each other) without being coupled or connected.

FIG. 4illustrates an exemplary fuel storage system400with fuel containers, in accordance with an embodiment. The fuel storage system400includes multiple support assemblies401,403and405that are configured, such as in a manner similar to that described in connection withFIG. 4, to support multiple fuel containers402,404and406, respectively. In an embodiment, support assemblies401,403and405can be stacked so as to prevent or reduce movement relative to one another. In some cases, the top portions of the fuel containers402,404and406stored therein may be sandwiched between the end support members of the support assemblies to further secure the fuel containers. In another embodiment, the fuel storage system400may include a multi-container support assembly rather than multiple detachable support assemblies. For example, a three-container support assembly may include three stacked single-container support assemblies where the end frames are welded together while the side frames may be detachable to facilitate loading and/or unloading of the fuel containers. In an embodiment, support assemblies401,403and405can be stacked so as to prevent or reduce movement relative to one another. The ends of the fuel containers402,404and406stored therein may be sandwiched between the end support members of the support assemblies. As discussed above, for each support assembly, the end support members may be connected by one, two or more side supports. A side support may include, for example, two substantially parallel side frames and zero or more truss members in between the side frames.

FIG. 5illustrates a portion of a fuel storage system500, in accordance with an embodiment. The fuel storage system500may include multiple support assemblies such as discussed above. In particular, the end frame of the support assembly may comprise two detachably coupled end support members. One of the two end support members may be removed to allow the loading of a fuel container. In particular, a fuel container502is loaded into a support assembly501(such as described in connection withFIG. 4). The neck portion504of the fuel container502may rest on a neck groove505on a first end support member506. Such a neck groove505may include a hollow concave shaped to interface with a neck portion of the fuel container. A second end support member (not shown) may have a matching neck groove such that when the second end support member is coupled to the first bottom end support member506, the neck portion504of the fuel container502is substantially enclosed, clamped or otherwise protected by an enclosure formed by the neck grooves of the first and second end support members. In various embodiments, the shape and dimensions (e.g., diameter, length) of the enclosure formed by the neck grooves may be configured to secure or protect the neck portion of the fuel container. For example, where the intersection of the neck portion is a circle, the shape of the enclosure may resemble a circle and an intersection of the neck grove505may resemble a portion of a circle such as a semi-circle. Where the intersection of the neck portion is a rectangle, the shape of the enclosure may resemble a rectangle. In an embodiment, the enclosure may form an opening through an end frame such that the top of the fuel container is visible from the other side of the end frame. In another embodiment, the enclosure may form a hollow cavity but not an opening in the end frame such that the top of the fuel container is not visible from the other side of the end frame.

Similarly, support assembly508(partially shown) provides an example of an assembled support assembly with a loaded fuel container. As illustrated, an end support member510with neck groove514is coupled to another end support member512with neck groove516are coupled such that the neck grooves514and516form an enclosure around the neck portion of the fuel container supported by the support assembly.

FIG. 5also illustrates exemplary methods for loading a fuel container into a support assembly and unloading a fuel container from a support assembly. In an embodiment, opposite-facing end support members may be coupled to one or more side frames such as side frame520to form a partially assembled support assembly such as501. At least one of the end support members is not added to allow an opening through with a fuel tank may be loaded into the partially assembled support assembly. For example, as illustrated inFIG. 5, the top end support member corresponding to the bottom end support member506is not assembled. In other words, one end of the side frames such as522are not coupled directly to an end support member. Next, a fuel container such as fuel container502may be loaded into the support assembly such that at least a portion of the fuel container (e.g., the neck portion) interfaces (directly or indirectly) with an end support member such as end support member506. Lastly, one or more end support member(s) similar to end support member510may be coupled to the existing end support member and/or one or more side frames such as side frame522to form a completely assembled support assembly such as support assembly508. For example, one such end support member may be attached to from an end frame for the top portion of the fuel container and another end support member may be attached to form an end frame for the bottom portion of the fuel container.

To unload a fuel container supported by a support assembly described herein, at least one of the end support members of the support assembly (e.g., end support frame510) before the fuel container may be lifted out of the support assembly. In some embodiments, at least one of the side frames may be also be removed to unload the fuel container.

FIG. 6illustrates an exemplary end support member600of a support assembly, in accordance with an embodiment. In an embodiment, one, two or more end support members may be coupled to each other to form an end frame for supporting the top or bottom portion of a fuel container. In an embodiment, the end support member600has a neck groove602shaped to interface with a portion such as a neck portion of a fuel container. For instance, the neck groove602may have a hemispherical shape or a portion thereof.

In an embodiment, the end support member600includes an inner surface604and an outer surface606that are substantially parallel to each other. The neck groove602may be situated at or near the middle of the inner surface. The inner surface604may be configured to be coupled or adjacent to an inner surface of another end support member such that the neck grooves of the two end support members form an enclosure to support the neck portion of a fuel container, as described above. The inner surface604may include characteristics that support the coupling with another inner surface. For example, the inner surface may include one or more holes605for bolting or other similar purposes. The holes605may be used to thread pipes, wires, or other objects through the fuel storage system.

The outer surface606may be configured to be coupled or adjacent to an outer surface of an end support member of another support assembly, such as when the support assemblies are stacked on top of each other. The outer surface606may include characteristics that support the coupling with another inner surface. For example, the inner surface may include one or more holes607for bolting or other similar purposes. The holes605may be used to thread pipes, wires or other objects through the fuel storage system.

In various embodiments, the end support member may be constructed to improve durability, weight-to-strength ratio, reusability and other characteristics. For example, the end support member600may include one or more holes608to reduce overall weight of the end support member. As another example, the end support member600may be symmetric along an axis running through the center of the neck groove602to provide even distribution of the weight along the axis. As yet another example, the end support member600may include an arch structure below the neck groove to distribute the load similar to a bridge. Further, as discussed above, components or portions of the end support member described herein may be constructed using any suitable material or combination of materials such as described in connection withFIG. 4.

In various embodiments, the pair of end support members that may be coupled to form an end frame in a support assembly may be substantially the same or different. For example, in an embodiment, the pair of end support members may be interchangeable. One end support member may be stacked on another in a symmetric or mirror-image fashion. In another embodiment, the more weight-bearing support member of the pair of end support members may be constructed to be sturdier (e.g., using a more durable material) than the less weight-bearing member. In some embodiments, two or more end support members may be used to provide support for an end (top or bottom) portion of a fuel container. For example, in an embodiment, four end support members each with a curved neck groove may be coupled in a circle to form a circular neck enclosure similar to described above, where each of the four end support members may occupy a quadrant of the end frame.

FIG. 7aillustrates another exemplary an end support member702, in accordance with an embodiment. In this example, the end support member702provides a neck groove704such as described in connection withFIG. 6. In some embodiments, the surface of the neck groove704may be constructed to provide support for at least a portion of a fuel container interfacing with the neck groove. For example, the surface of the neck groove704may include a plurality of threaded grooves substantially perpendicular to the longitude of the neck groove to provide better support of the neck portion of the fuel container. For example, the grooves may be provided to increase the friction between the neck portion of the fuel container and the end support member so as to prevent or reduce the movement of the fuel container longitudinally relative to the end support member.

In an embodiment, the end support member702also includes an inner surface706that may be coupled with an inner surface of another end support member of the same support assembly. In various embodiments, the pair of end support members may be coupled in any suitable manner. For example, in an embodiment, a wedge attached to the inner surface of an end support member may be engaged with a matching groove on the inner surface of another end support member. The wedge and groove may be of any shape or dimensions. For example, the wedges may be of a tapered shape such as illustrated by tapered wedge708and the corresponding groove may be of a tapered shape such as illustrated by grooves710and712. In some embodiments, shapes of wedges and grooves other than illustrated may be used. In general, any shaped features such as illustrated may be provided to prevent the end support members from moving laterally or away from each other.

In some embodiment, an end support member may provide one or more wedge and/or one or more grooves. In an embodiment, the longitude of a groove may intercept with an edge of the inner surface of the end support (such as illustrated by groove710and712) so that the groove may engage with a corresponding wedge of another end support member when the pair of end support members move relatively in a direction substantially parallel to the longitude of the groove.

In an embodiment, one or more such grooves may be provided for one end support member, the longitudes of the grooves may be associated with one or more directions. Such shaped features may be separate from the end support members or built-in as part of the end support members. For example, in an embodiment, one or more separate tapered wedges708or other shaped objects may be pressed into (or otherwise inserted into) one or more channels formed by matching grooves of two end support members when the end support members are stacked as mirror-images of each other.

In an embodiment, the end support member702may also include one or more openings, such as openings714and716. In some instances, such openings may be used for venting excess pressure from a fuel container or for threading pipes or other objects through.

FIG. 7billustrates an exemplary pair of a wedge and a groove, in accordance with an embodiment. The example provides an intersection view of a tapered wedge720of an end support member724and a tapered groove722of an end support member726such as described above in connection withFIG. 7a. The tapered groove722may be configured to engage with a portion of the tapered wedge720when the tapered wedge720is slid into the tapered groove722, for example, in a direction substantially parallel to the longitude of the groove722. In some embodiments, a gap728between the members724and726may result from a portion of the tapered wedge720that is not does not fit in tapered groove722. Such a gap728may be desirable in some instances. For example, the gap may facilitate easy coupling and/or decoupling of a pair of end support members. Alternatively, there may be no gap between the coupled end support members. In some embodiments, wedge and the grove may be of shapes other than those illustrated herein.

FIG. 8aillustrates another exemplary end support member800, in accordance with an embodiment. In this example, the end support member800may be similar to the end support member702discussed in connection withFIG. 7except that the end support member800additionally includes a trailing edge fairing802. Such a trailing edge fairing802may be attached (detachably or not) to a surface or side803of an end support member. In an embodiment, such a fairing may be used exposed outside a housing (e.g., a cab of a vehicle) for a support assembly while the rest of the support assembly may be covered or enclosed by the housing. The fairing may be used to removing the movement of the end support assembly, for example, relative to the housing of the support assembly.

In some embodiments, the fairing may be used to reduce drag that may exist, for example, when the end support member moves through the air as part of a fuel storage system mounted on a moving vehicle. For example, the fairing802may be coupled to the end support member800using a bolt807. In some embodiments, the trailing edge fairing802may be attached or coupled to various portions of the end support member800based, for example, on the direction of the wind. For example, the configuration illustrated inFIG. 8amay be used to reduce drag caused by wind blowing in the direction indicated by the arrow804. The trailing edge fairing may be attached to the other side806of the end support member800if the direction of the wind is reversed. In some embodiments, two or more edge trailing fairing may be provided, for example, one on each side of the end support member. In various embodiments, the trailing edge fairing may be constructed with material(s) similar or different to those used for the support assemblies based on considerations such as cost, weight, durability and other factors. For example, the trailing edge fairings may be constructed using light-weight materials such as aluminum or polymer.

FIG. 8billustrates exemplary components of a trailing edge fairing808, in accordance with an embodiment. This example provides a top intersection view of the fairing components including those illustrated inFIG. 8a. In this example, the trailing edge fairing808may include a fairing portion814that may be used to reduce drag. The fairing portion may be attached to an end support member, for example via nuts and bolts through one or more holes810and/or via a protruding wedge812that may fit into a groove along a side of the end support member. In other embodiments, the faring may be attached to the end support member via other means.

In an embodiment, one or more plate members816may be used to provide a smooth surface of an end support member to reduce drag, for example, by covering up the gap805between the two ends of the end support member. In some embodiments, such a plate members816may be coupled to an end support member with any fastening members such as glues, joints, tongue and grove, bolts, and the like.

FIG. 9illustrates another exemplary end support member900, in accordance with an embodiment. In this embodiment, the inner surface of the end support member may include one or more slightly-raised plates902. Such plates may include holes904used to for securing the end support member900with another end support member such as via nuts and bolts, wires, strings, ropes, buckles, pins, rings, and the like. In some cases, the raised plates may interface with a corresponding structure on the other end support member to provide stability. In some embodiments, the raised plates902may also be used to provide some spacing between the surfaces of end support members.

In an embodiment, the end support member includes hollow interiors906used to reduce overall mass of the end support member, increase the strength-to-weight ratio, providing housing for other components (e.g., piping) and the like.

As discussed above, the end support member may provide a neck groove for supporting the neck portion of a fuel container. In some embodiments, the neck portion of the fuel container may directly rest on such a neck groove. In other embodiments, an extra padding or layer may be provided between the neck portion of the fuel container and the neck groove. Such a padding or layer may be provided to better secure and/or protect the fuel container, reduce wear-and-tear of the end support member, provide a customized fit for the fuel container, and the like.FIG. 10illustrates an exemplary implementation1000of such an extra layer between a portion of a fuel container and a neck groove of a support assembly, in accordance with another example. In this example, a collar1002may be (detachably or non-detachably) coupled to the neck portion of a fuel container (not shown) before the neck portion is placed on the neck groove1004of an end support member. Such a collar1002may be used to absorb and/or reduce damage to the fuel container, to better secure the neck portion (e.g., to prevent slipping), to provide adapting between the neck portions of different sizes and a universal neck groove, and the like. When worn, such a collar, rather than the end support member, may be replaced thereby increasing the durability of the end support member.

Various methods may be used to couple such a collar1002to the neck portion of a fuel container. For example, in an embodiment, interfacing surfaces of the collar and the neck portion of the fuel container include threaded grooves so that the collar may be screwed onto the neck portion. In an embodiment, the collar may include longitudinal slit and the collar may be resiliently spreadable at the slit to enclose a portion of a neck portion of a fuel container. As another example, two half-spherical collars may be clamped around the neck portion, for example, via bolting.

In some embodiments, the collar1002may act as an adapter between the neck portion of a fuel container and a neck groove. For example, in an embodiment, such collars may be used to adapt neck portions of different dimensions (e.g., diameters) to a universal neck groove. In various embodiments, the dimensions (e.g., inner diameter, outer diameter) of the collar may vary according to dimensions of the neck grooves, the dimensions of the neck portion of fuel containers, the environment and the like. In various embodiments, the material(s) used to construct such collars may be determined by cost, strength-to-weight ratio, impact requirement, the material for the neck portion of the fuel container and/or neck groove, the environment and the like. For example, the collars may be made from elastic, shock-absorbing, and/or high-friction material(s).

According to an aspect of the present invention, the fuel storage system described herein provides mechanisms for releasing pressure buildup in the fuel containers supported therein. In warm weathers, gaseous pressure may build up in a fuel container. Such pressure buildup may be undesirable and/or dangerous unless the excess pressure is timely released.FIGS. 11a-billustrate an exemplary mechanism for pressure release in a fuel storage system, in accordance with an embodiment. As illustrated inFIG. 11a, an end support member1102may include a main through-hole1104(similar to the opening714ofFIG. 7) on an inner surface1108of the end support member1102. Such a through-hole1104may be substantially aligned with a similar through-hole1105on the opposing outer surface1109of the end support member1108as well as other similar through-holes on the surfaces of other end support member(s) configured be stacked or placed adjacent to the end support member1108to form a main channel1110in which excess pressure may be released.

In an embodiment, the end support member1102may include a side through-hole1106(similar to the opening716ofFIG. 7) that may open into the main channel1110described above. In an embodiment, excess pressure in a fuel container supported by the end support member1102may be released through the side through-hole1106into the main channel1108. The side through-hole1106may be connected to a pressure release valve coupled to the fuel container. Such a pressure release valve may be located near the neck portion of the fuel container. In an embodiment, excess pressure may be carried by pipes located within the hollow channels connecting the through-holes described above. Such pipes may be made from materials such as polymer, aluminum or the like. In another embodiment, at least some portions of such hollow channels may not house any such pipes.

As discussed above, the through-holes of end support members for multiple support assemblies may line up approximately to support effective release of excess pressure across multiple fuel containers.FIG. 11billustrates an exemplary fuel storage system with pressure release, in accordance with at least an embodiment. In this example, multiple support assemblies1120,1122and1124are stacked on top of each other. Each support assembly has a pair of end support members such as end support members1126and1128. The pair of end support members may have through-holes that line up to form the main channel1130such as similar to the main channel1110discussed in connection withFIG. 11a. In addition, one or both of the end support members have a side through-hole for releasing pressure of an individual fuel container into the main channel1130. When multiple such support assemblies are stacked such as illustrated, excess pressure from the fuel containers supported by these support assemblies may be released via the individual side through-holes into the common channel1130. In various embodiments, components forming the main channel may or may not be fluid-tight. For example, in an embodiment, fuel may escape or vent through the components, such as a gap between the end support member1126and1128.

As discussed above, techniques described herein may provide a modular and simplified approach to supporting and/or transporting fuel containers.FIG. 12illustrates a process or method1200for assembling a fuel container support assembly to support a fuel container, in accordance with an embodiment. In an embodiment, the process1200includes providing1202a partially assembled support assembly such as illustrated by the support assembly501ofFIG. 5. In an embodiment, providing the partially assembled support assembly includes connecting two opposite facing end support members with at least two side frames, for example, to form a substantially rectangular prism shape. Multiple support assemblies thus shaped can be easily stacked or otherwise arranged in a spatially efficient manner. In other embodiments, the support assembly may have other shapes. In some embodiments, providing the partially assembled support assembly includes connecting at least one of the end support members with at least one of the side support members. In some cases, at least one of the end support members and/or side support member (or a component thereof) are not assembled to allow the fuel container to be loaded into the support assembly. For example, one of the end support members forming a neck enclosure for a neck portion of the fuel container may not be attached. In some embodiments, a side support member or a component thereof (e.g., a side frame) may not be attached to allow the loading of the fuel container.

In an embodiment, the process1200includes loading1204a fuel container into the partially-assembled support assembly described above. In some embodiments, a portion such as the neck portion of the fuel container may interface with one of the end support member. For example, the neck portion may rest upon a neck groove provided by the end support member, such as discussed in connection withFIG. 5. In some embodiments, a collar or a similar member may be coupled or attached to the neck portion before the neck portion interfaces with the end support member to provide additional support and/or adaptation, such as discussed in connection withFIG. 10.

In an embodiment, process1200includes complete1206assembly of the support assembly. Completing the assembly of the support assembly may include attaching at least one end support member and/or side frame to the partially-assembled support assembly. For example, to complete the assembly, one or more end support members that complete the neck enclosure of the fuel container may be coupled to the already-assembled end support member(s) forming the neck enclosure. Additionally, the end support member(s) may be coupled to existing side support members or components thereof (e.g., side frames) to complete the assembly.

In some embodiments, additional and/or different steps may be provided to assemble and load the support assembly. For example, in an embodiment, one or more side frames may be attached after the complete assembly of the end frames. For example, the end support members may be clasped around the neck portion of a fuel container first. Then, the side support members may be attached to the end support members to protect the body portion of the fuel container. Lastly, another set of end support members may be attached to the side support members to complete the assembly of the support assembly. In an embodiment, a partially-assembled support assembly comprises some or all of the side support members already attached to a first end frame. The first end frame may be for the bottom portion or the top portion of the fuel container. The fuel container is then loaded into the partially-assembled support assembly before a second end frame is assembled. Assembling the second end frame may include assembling components of the end frame as well as attaching the second end frame to the existing side support members.

In addition, multiple support assemblies may be coupled, stacked or otherwise arranged according to various configurations, such as those discussed in connection withFIG. 2, before or after one or more fuel containers are loaded into the support assemblies. In an embodiment, each of the multiple support assemblies is fully assembled and/or loaded before the support assemblies are coupled or arranged according to a configuration. For example adjacent support assemblies may be fastened using any suitable means such as bolts, wires, wedges and the like. For another example, support assemblies may be placed adjacent to each other without being coupled. In another embodiment, some or all of support assemblies may be partially assembled when they are configured with other support assemblies. For example, in an embodiment, one or more support assemblies may only include some of the end support members and/or side supports necessary to complete the assembly. In some cases, the partially assembled support assemblies may include loaded fuel containers. The partially assembled support assemblies may be configured with other partially assembled and/or fully assembled support assemblies. Subsequent to or during such configuration, the partially assembled support assemblies may be fully assembled such as by adding an end frame and/or a side frame, loading a fuel container and the like.

In some embodiments, pipes may be installed through the openings provided by the fuel container support assemblies such as described in connection withFIGS. 11a-b. Such pipes may be configured to facilitate the release of excess pressure from the fuel containers, fueling, or other purposes. The installation of the pipes may occur before, during, or after the loading of the fuel containers. The installation of the pipes can also occur before, during or after the configuration of the support assemblies of the fuel storage system.

In various embodiments, a reverse process of the process1200may be followed to allow disassemble and/or unloading of the fuel container from the support assembly. For example, to unload a fuel container, at least an end support member and/or side support member may be removed from the support assembly. In some instances, one or more end support members may be detached from other end support members and/or side support members. For example, an end support member supporting the neck portion of the fuel container may be removed to allow the fuel container to be unloaded from the support assembly. Alternatively or additionally, an entire end frame and/or a side support member can be removed to unload the fuel container. The components to be disassembled from the support assembly and the order of such disassembly may vary based on considerations such as specific structure of the support assembly, cost, convenience, space, weight and dimensions of the fuel container, configuration of the fuel storage system, and/or the like.

In various embodiments, the number and/or arrangement of the support assemblies and/or members thereof may be based on the characteristics of the environment where the fuel storage system is used such as the type and dimension of the cab of a vehicle. In an embodiment, such environment information is obtained and analyzed, for example, via a computerized modeling tool to determine a configuration (e.g., number, types and arrangement) of the support assemblies. In some embodiments, such determination may be aimed at optimizing the cost, space and/or other configurable considerations. According to the determined configuration, the support assemblies may be selected, assembled and/or arranged (e.g., connected) such as discussed above.

As discussed above, the fuel storage system may be mounted, for example, to a vehicle according to various configurations such as discussed in connection withFIG. 1. Alternatively, the fuel storage system may be used in a stand-alone fashion. As described above, in an embodiment, the support assemblies may include a small number (e.g., four, six or eight) of modular members with a small number (e.g., two, three or four) of distinct shapes that are easy to manufacture, assemble, dissemble and/or reuse. In some embodiments, the modular members are also designed to be durable and lightweight.