Abstract:
A modular fuel storage system can include a container, a cover, a storage tank and fuel fill and delivery lines. The container can define an interior space therein and the cover can be configured to engage the container to enclose the interior space. The storage tank can be configured to store and selectively deliver a gaseous fuel. The fuel fill and fuel delivery lines can each be fluidly connected to the storage tank. The fill and delivery lines can each have a coupling connector extending external to the container and terminating in a recess formed in an exterior of the container. The modular fuel storage system can be configured to be assembled in the vehicle such that the cover forms a portion of a floor of the vehicle.

Description:
FIELD 
       [0001]    The present disclosure relates generally to a fuel storage system and, more particularly, to a modular fuel storage system for a vehicle. 
       BACKGROUND 
       [0002]    The use of gaseous fuels, such as hydrogen or compressed natural gas, for vehicles is generally known. Such fuels can represent an alternative to petroleum as a fuel source for motor vehicles, but are generally required to be stored at an elevated or high pressure in a storage tank. Typical storage tanks and their associated mounting systems for compressed gaseous fuels include various components that can raise the cost and complexity of manufacturing an alternative fuel vehicle. In addition, such storage tank systems often result in a loss of interior cabin volume or trunk volume in an automotive vehicle. Thus, there remains a need in the relevant art for a modular fuel storage system that overcomes the aforementioned and other disadvantages. 
       SUMMARY 
       [0003]    In one form, a modular fuel storage system for a vehicle is provided in accordance with the teachings of the present disclosure. The modular fuel storage system can include a container, a cover, a storage tank and fuel fill and delivery lines. The container can define an interior space therein and the cover can be configured to engage the container to enclose the interior space. The storage tank can be configured to store and selectively deliver a gaseous fuel. The fuel fill and fuel delivery lines can each be fluidly connected to the storage tank. The fill and delivery lines can each have a coupling connector extending external to the container and terminating in a recess formed in an exterior of the container. The modular fuel storage system can be configured to be assembled in the vehicle such that the cover forms a portion of a floor of the vehicle. 
         [0004]    In another form, a vehicle is provided in accordance with the teachings of the present disclosure. The vehicle can include a modular fuel storage system having a container, a cover, first and second storage tanks, fuel fill and delivery lines and an access door. The container can define an interior space therein and the cover can be configured to engage the container to enclose the interior space. The first and second storage tanks can each be configured to store and selectively deliver a gaseous fuel. The fuel fill and delivery lines can each be fluidly connected to the first and second storage tanks. The fuel fill and delivery lines can each have a coupling connector extending external to the container and terminating in a recess formed in an exterior of the container. The access door can be formed in at least a sidewall of the container, and can be removably coupled to the container. An aperture can be formed in a floor of the vehicle and can be positioned between longitudinally extending frame rails of the vehicle and front and rear wheels of the vehicle. The modular fuel storage system can be configured to be positioned in the aperture and fixed to the vehicle such that the cover forms a portion of the floor of the vehicle. The access door can be accessible from an underside of the vehicle to provide access to control features of the storage tanks while the cover remains engaged to the container. 
         [0005]    Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims and the drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be understood that the detailed description, including disclosed embodiments and drawings referenced therein, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the present disclosure, its application or uses. Thus, variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a partial perspective view of an exemplary modular fuel storage and delivery system shown in association with an exemplary vehicle according to the principles of the present disclosure; 
           [0007]      FIG. 1A  is a partial perspective view of the exemplary modular fuel storage and delivery system of  FIG. 1  positioned in the exemplary vehicle according to the principles of the present disclosure; 
           [0008]      FIG. 2  is a partial top perspective view of the exemplary modular fuel storage and delivery system of  FIG. 1  with a load floor cover removed for clarity of illustration according to the principles of the present disclosure; 
           [0009]      FIG. 3  is an exploded view of the exemplary modular fuel storage and delivery system of  FIG. 1  according to the principles of the present disclosure; 
           [0010]      FIG. 4  is a partial bottom perspective view of the exemplary modular fuel storage and delivery system of  FIG. 1  with a side access door removed for clarity of illustration according to the principles of the present disclosure; 
           [0011]      FIG. 5  is a partial side view of the exemplary modular fuel storage and delivery system of  FIG. 1  with the cover removed and a portion of a container cut away according to the principles of the present disclosure; and 
           [0012]      FIG. 6  is a partial bottom view of the exemplary modular storage and delivery system positioned in the exemplary vehicle according to the principles of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    With initial reference to  FIG. 1 , an exemplary modular fuel storage system  10  for storage and delivery of a compressed or high pressure gaseous fuel is shown in association with an exemplary vehicle  14  in accordance with the present teachings. In one exemplary configuration, the gaseous fuel can be compressed natural gas. It will be appreciated, however, that various other gaseous fuels can be utilized with the modular fuel storage system  10 , such as propane or hydrogen. 
         [0014]    In the exemplary configuration illustrated, vehicle  14  is a motor vehicle, such as a minivan, and can include a forward end  18 , a rearward end  22 , a first door opening  26 , a second door opening  30 , and a floor  34 . In this exemplary configuration, the second door opening  30  can be associated with a second row of seating (not specifically shown) in the minivan, and an aperture  40  can be formed in the floor for receipt of the modular fuel storage system  10 , as will be discussed in greater detail below. It should be appreciated that while the discussion will continue with reference to vehicle  14  being a minivan, the modular fuel storage system  10  can be associated with various different vehicle configurations and models. 
         [0015]    In one exemplary configuration, the modular storage system  10  can be positioned in a central location of the vehicle and, when utilized in a minivan, can optionally take the place of stowage tubs typically associated with a collapsible second row of seating. It should be appreciated, however, that the modular storage system  10  can also be positioned at a rearward area of the vehicle. The modular fuel storage system  10  can be received in a manufacturing plant as a pre-certified assembly ready to be positioned in the vehicle thereby eliminating a need for installing various individual components associated with modular storage system  10 . The modular storage system  10  can also be sealed relative to an interior of the vehicle with a sealable cover that forms a portion of the floor  34  of vehicle  14 , as will be discussed in greater detail below. 
         [0016]    With additional reference to  FIGS. 2-6 , modular storage system  10  can include a container or tub  54 , a cover  58  and an access door  62 , as generally shown in  FIGS. 2-4 . Container  54  can be configured to receive one or more storage tanks, as generally shown in  FIGS. 1-5 . In the exemplary configuration illustrated, container  54  can be configured to house two storage tanks, each being of a different size, as will be discussed in greater detail below. Container  54  can include a generally rectangular shape  66  having a longer lateral width than length, where the lateral width can correspond to a cross-car direction, as generally shown in  FIGS. 1 and 1A . In this regard, container  54  can include first and second opposed walls or sides  70 ,  74  ( FIGS. 1 and 2 ) and third and fourth opposed walls or sides  78 ,  82 . 
         [0017]    The container  54  can include an outer perimeter  88  sized to be received in and pass through the aperture  40  of floor  34 , as generally shown in  FIG. 1  with reference to  FIG. 6 . An upper area or end  92  of container  54  can include a flange  96  extending beyond perimeter  88  and configured to engage a portion of an upper side  102  of floor  34  adjacent aperture  40  when container  54  is positioned therein. A lower side of flange  96  can be sealingly engaged to vehicle floor  34  when container  54  is installed in aperture  40 . In one exemplary configuration, the lower side of flange  96  can be glued to the upper side  102  of floor  34  to sealingly secure container  54  thereto. An upper side  108  of flange  96  can also receive a seal  112  associated with container  54  and/or cover  58  to seal cover  58  to container  54 . 
         [0018]    Container  54  can include a greater height or depth  122  adjacent third side  78  as compared to fourth side  82  so as to facilitate housing storage tanks of different sizes, as generally shown in  FIG. 5  where storage tank  126 A positioned relative to third side  78  has a larger diameter than storage tank  126 B positioned relative to fourth side  82 . A plurality of depressions or recessed areas  130 ,  134 ,  138  can be formed in the exterior of container  54  for facilitating external access to fuel line and coolant line connections, as will be discussed in greater detail below. 
         [0019]    An access aperture  144  can be formed in a side of container  54 , such as the first side  70  shown in  FIG. 4 , to facilitate access to operating and control features of the storage tanks  126 A,  126 B while the modular fuel storage system is assembled to vehicle  14 . In this regard, access aperture  144  in connection with removable access door  62  can provide selective access to the operating and control features of tanks  126 A,  126 B without having to remove cover  58 . In one exemplary configuration, access door  62  can form a sealed connection to container  54  when coupled thereto. 
         [0020]    In one exemplary configuration, the access aperture  144  can be formed so as to extend from third side  78  to fourth side  82  and intersect with each of the respective recessed areas  134 ,  138 , as shown for example in  FIG. 4 . Access door  62  can be sized and shaped to cover aperture  144  and conform to a portion of outer perimeter  88  adjacent aperture  144 , as generally shown in  FIG. 4  with reference to  FIG. 2 . In the exemplary configuration illustrated, opposed ends  152  of access door  62  can form part of recessed areas  134 ,  138  and can engage seals  154  to seal connections to feed and supply lines  162 ,  166  that extend from an inside or interior  156  of container  54  into the recessed areas  134 ,  138 . The access door  62  can also include a recessed area  158  sized and shaped to provide access to a shut-off valve  174  without having to remove access door  62 , as generally shown in  FIG. 2  with reference to  FIG. 4 . 
         [0021]    The container  54  can also include a stepped configuration  178  extending generally from the flange  96  along the third side  78  at least partially toward a floor or bottom  182  of container  54 . An intermediate member  186  can extend upward from the stepped configuration  178  so as to be flush or substantially flush with a plane encompassing flange  96 , as generally shown in  FIG. 2 . Intermediate member  186  can serve as a structural member to support a portion of seal  112  as well as a pair of bulkheads  190  that can optionally be positioned between intermediate member  186  and respective sides  70 ,  74 . A pair of stepped areas  194  can be formed by the bulkheads  190 , intermediate member  186  and associated sides of the container, as also shown in  FIG. 2 . These stepped areas  194  can receive optionally integrated seat mounting brackets  202 , as can be seen in  FIGS. 2 and 3 . 
         [0022]    It should be appreciated that modular fuel storage system  10  can include container  54  with or without the bulkheads  190 , intermediate member  186  and seat mounting brackets  202 . In a configuration including seat mounting brackets  202 , seal  112  and cover  58  can follow a perimeter  204  established by the sides  70 ,  82 ,  84 , the bulkheads  190  and the intermediate member  186 , thereby providing access to the seat mounting brackets  202  while sealing an interior of container  54  within perimeter  204 . In a configuration that does not include optional seat mounting brackets  202 , cover  58  and seal  112  can align with perimeter  204  or, alternatively can align with a perimeter  206  ( FIG. 2 ) established by flange  96 . In the latter scenario, the bulkheads  190 , intermediate member  186  and seat mounting brackets  202  can optionally not be included with the modular fuel storage system  10 . 
         [0023]    As briefly discussed above, container  54  can house one or more compressed or high pressure storage tanks, such as tanks  126 A and  126 B. In the exemplary configuration illustrated, two cylindrical tanks  126 A and  126 B can be housed in the interior  156  of container  54  with one of the tanks,  126 A, including a larger diameter than tank  126 B. It will be appreciated, however, that a single tank or multiple tanks of the same or varying widths or diameters can be utilized with container  54 . In the exemplary configuration illustrated, tanks  126 A and  126 B can be positioned contiguous to each other and can extend along a longitudinal length of container  54 , which when positioned in vehicle  14 , can extend cross-vehicle or substantially perpendicular to a longitudinal axis of vehicle  14 . 
         [0024]    As container  54  can be sealed relative to the interior of the vehicle when cover  58  is removably secured thereto, one or more flapper or check valves or vents  210  can be provided in one of the sides  70 ,  74 ,  78 ,  82  of container  54 . In one exemplary configuration illustrated in  FIG. 3 , valves/vents  210  can be positioned in side  78 , which is orientated facing rearward when installed in vehicle  14 . This rearward facing orientation can shield or substantially shield valve  210  from road debris and the like during operation of vehicle  14 . It should be appreciated, however, that the valves/vents can also be positioned in container  54  such that they are forward or side facing when storage system  10  is installed in vehicle  14 . 
         [0025]    Tanks  126 A,  126 B can include a retainer assembly  212  configured to support and maintain a predetermined position of tanks  126 A,  126 B in the interior  156  of container  54  and relative to the vehicle  14 . Retainer assembly  212  can include one or more tank strap sets  216  each having a housing  218  with one or more ring-shaped portions  220  sized and shaped to correspond to the width and exterior shape of tanks  126 A,  126 B, as generally shown in  FIG. 3 . Each tank strap set  216  can include a first member  226 . The first member  226  can extend from a side of housing  218  and can be configured to be secured to the vehicle  14  adjacent aperture  40  with fasteners  228 . In one exemplary configuration, the first member  226  can be secured to vehicle  14  to thereby removably secure tanks  126 A,  126 B thereto, as generally shown in  FIG. 2  with reference to  FIGS. 1 and 1A . In this exemplary configuration, the retainer assembly  212  can secure the tanks  126 A,  126 B to the vehicle  14  independent of the container  54 . 
         [0026]    In the exemplary configuration illustrated, retainer assembly  212  can include a pair of tank strap sets  216  each having two ring-shaped portions  220  for engagement with tanks  126 A,  126 B, as shown for example in  FIGS. 2 and 3 . A retention and handle assembly  244  can be integrally formed with or coupled to retainer assembly  212 , as generally show in  FIGS. 2 and 3 . Retention and handle assembly  244  can include a lower portion  248  and an upper portion  250 . The lower portion  248  can be positioned in a lower space  254  formed between ring-shaped portions  220  such that the lower portion  248  extends substantially along a longitudinal length of tanks  126 A,  126 B and connects to each tank strap set  216 . In the exemplary configuration illustrated, each tank strap set  216  is positioned relative to opposed ends of tanks  126 A,  126 B, as shown for example in  FIG. 2 . 
         [0027]    The lower portion  248  can be connected at each end thereof to upper portion  250  via a shoulder bar  256 , as shown for example in  FIG. 3 . Upper portion  250  can extend, in one exemplary configuration, along an upper space  258  between tanks  126 A,  126 B from the first side  70  to the second side  74 , as generally shown in  FIG. 2 . Tightening the upper portion  250  to the shoulder bar  256  can force the ring shaped portions  220  of tank strap sets  216  downward in space  258  thereby tightening tank strap sets  216  around tanks  126 A,  126 B. In one exemplary configuration, ring-shaped portions  220  can include a rubber liner  260  on an inside thereof configured to engage tanks  126 A,  126 B when secured thereto, as shown for example in  FIG. 3 . Upper portion  250  can thus include a longer longitudinal length than lower portion  248  and can be secured to vehicle  14  at its opposed ends, as also shown in  FIG. 2  with reference to  FIG. 1A . In operation, retention and handle assembly  244  can both serve as a structure to secure tanks  126 A,  126 B to each other and to vehicle  14  (e.g., floor  34 ) via fasteners  228 , as well as a mechanism for carrying tanks  126 A,  126 B to and from container  54 . For example, once the relevant portions of handle assembly  244  are unsecured from vehicle  14  and container  54  (along with first members  226 ), the upper portion  250  of retention and handle assembly  244  can be grasped to lift and remove tanks  126 A,  126 B from container  54  and vehicle  14 . Tanks  126 A,  126 B can then be carried while being coupled to each other via assembly  244 . 
         [0028]    With particular reference to  FIG. 5  and continuing reference to  FIGS. 1-4  and  6 , tanks  126 A,  126 B can each include a valve  270  operably connected to a pressure regulator  274 . Pressure regulator  274  can be fluidly coupled to both valves  270  along with the feed and supply lines  162 ,  166  and a filter system  280 , as generally shown in  FIG. 5  with reference to  FIG. 3 . Coolant lines  284  can be coupled to the pressure regulator  274  and can be operable to control a temperature of the pressure regulator  274  and associated control components as a result of pressure changes during operation or use of compressed natural gas stored in tanks  126 A,  126 B. 
         [0029]    With particular reference to  FIGS. 2 and 4 , the recessed areas  130 ,  134  and  138  can be sized and shaped so as to extend beyond the respective coolant lines  284  external connection  264 , supply line  166  external connection  268 , and fill line  162  external connection  272 . This feature can, among other things, serve to protect the external connections  264 ,  268 ,  272  during transport, vehicle assembly and operation or modular fuel storage system  10 . The modular fuel storage system  10  can be configured as a pre-certified, drop-in modular assembly for its associated vehicle. Necessary connections to vehicle  14  can be accomplished via the external connection capability of container  54  (e.g., external connections  264 ,  268  and  272 ). In the exemplary configuration illustrated, external connections  264 ,  268  and  272  can be quick-connections for ease of manufacturability and/or serviceability. 
         [0030]    With particular reference to  FIGS. 2 ,  4  and  6 , modular fuel storage system  10  can include one or more skid plate support straps  290 . Straps  290  can be sized and shaped to conform to an outer shape of container  54  so as to engage at least a portion of sides  78  and  82  and bottom  182 . In the exemplary configuration illustrated, modular fuel storage system  10  can include two straps that extend along bottom  182  and sides  78 ,  82  so as to be secured to an underside of floor  34  (or adjacent chassis/frame component), as generally shown in  FIG. 4  with reference to  FIG. 6 . Straps  290  can be structurally designed to not only aid in supporting container  54 , but also serve as check straps or skid plates to protect the container from any potential under-vehicle hazards. For example, straps  290  can prevent or substantially prevent the bottom  182  of container  54  from being dented or pushed inward due to contact with such under-vehicle hazards. 
         [0031]    In operation, and with particular reference to  FIG. 1 , modular fuel storage system  10  can be assembled to minivan vehicle  14  through the second or rear door opening  30 . The modular system  10  can be positioned in aperture  40  from an upper side  102  of floor  34 , as also shown in  FIG. 1 . The flange  96  can be sealed to floor  34  and the cover  58  can be semi-permanently sealed to container  54  so as to seal modular system  10  relative to an inside of the passenger compartment of vehicle  14 , while allowing the interior  156  of container  54  to vent to the atmosphere via vents or valves  210 . As discussed above, cover  58  can form a portion of floor  34  of vehicle  14  when modular system  10  is assembled thereto. In one exemplary configuration, the modular system  10  can be installed in the vehicle as a complete, pre-certified assembly with all necessary connections to vehicle components being accessible and handled external to the interior  156  of container  54 . 
         [0032]    The modular fuel storage system  10  can be centrally positioned in vehicle  14  between front and rear axles/wheels  294 ,  298 , as generally shown in  FIGS. 1 and 6 . In the exemplary configuration illustrated in  FIGS. 1 and 6 , the modular system  10  can be positioned between longitudinally extending frame rails  302 ,  306  and vehicle cross-members  310 ,  314 . In this exemplary configuration, straps  290  can be coupled to cross-members  310 ,  314 . 
         [0033]    It should be understood that the mixing and matching of features, elements and/or functions between various examples may be expressly contemplated herein so that one skilled in the art would appreciate from the present teachings that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above.