Tanks forming rack superstructure

Abstract

A support structure which includes tank formed rack comprising at least two modules affixed to each other via attached bases and a method of reduced weight storage of fuel tanks also for use in motor vehicles wherein the fuel tanks via attached bases are used to form a portion of the rack superstructure.

Claims

1. A fuel tank rack structure comprising at least two modules (10/10) affixed together, wherein each module comprises: a cylindrical fuel tank (15); two front bottom bases (30A/30A) and two back bottom bases (30B/30B) affixed to the bottom of the cylindrical fuel tank (15); two front top bases (20A/20A) and two back top bases (20B/20B) affixed to the top of the cylindrical fuel tank (15); wherein the at least two modules are fastened together in a vertical arrangement with the modules fastened together by affixing the front bottom bases of each successively higher module (10) to the front top bases of the previous module (10) and affixing the back bottom bases of each successively higher module (10) to the back top bases of the previous module (10); wherein the top and bottom bases are sized to allow the modules (10/10) to be fastened together in a vertical arrangement without allowing the tanks (15) to touch; and, wherein the front top bases and the back top bases comprise an interface (22) corresponding to the curvature of the fuel tank, a head latch (25) extending upwards, and a pin guide (27) disposed in the head latch; the front bottom bases and the back bottom bases comprise an interface (22) corresponding to the curvature of the fuel tank, a head catch (35) forming a well in the bottom base, and a pin guide (27) disposed in the head catch; and, the pin guides of each pair of top and bottom bases that are affixed together are aligned and a fastener (37) is inserted through the aligned pin guides and fixed in place.

2. The fuel tank rack structure of claim 1 wherein the fuel tanks (15/15) in each module form a portion of the superstructure of the rack (280).

3. The fuel tank rack structure of claim 1 wherein, for each fuel tank (15), an outer edge to edge distance between each of the two front bottom bases (30A/30A), two front top bases (20A/20A), two back bottom bases (30B/30B), and two back top bases (20B/20B) is less than a diameter of the fuel tank (15).

4. The fuel tank rack structure of claim 1 wherein, for each fuel tank (15), an outer edge to edge distance between the two front top bases (20A/20A) and the two front bottom bases (30A/30A) and an outer edge to edge distance between the two back bottom bases (30B/30B) and two back top bases (20B/20B) is greater than a diameter of the fuel tank (15).

Description

DRAWINGS

(1) The above-mentioned features of the present disclosure will become more apparent with reference to the following description taken in conjunction with the accompanying drawings wherein like reference numerals denote like elements and in which:

(2) FIG. 1A shows aspects of a fuel tank rack module;

(3) FIG. 1B shows a front view of aspects of the fuel tank rack module of FIG. 1A;

(4) FIG. 2A shows a perspective view of aspects of the pin assembly of two rack modules;

(5) FIGS. 2B shows a close up of aspects of an assembly feature for rack modules;

(6) FIG. 3 is a front view of aspects of a first sub-rack module of FIGS. 2 and 4;

(7) FIG. 4 shows a perspective view of aspects of an assembly of three rack modules;

(8) FIG. 5 is a cut away view of the assembly of three rack modules of FIG. 4 along line A-A;

(9) FIG. 6 shows aspects of attachment of two rack modules to a vertical anchor;

(10) FIG. 7 shows aspects of an alternative bolt attachment method; and,

(11) FIG. 8 shows a perspective view of aspects of 3 rack modules prior to mounting to a vertical anchor.

(12) As shall be appreciated by those having ordinary skill in the art, the figures are not to scale, and modifications to scale within a figure or across the figures are considered within the present disclosure.

FURTHER DESCRIPTION

(13) Unlike traditional rack and tank support system with a steel rack/cage with compartments to hold tanks Wherein the rack is a unitary structure to which tanks are secured and the tanks form no part of the superstructure, disclosed herein are aspects of exemplary systems and methods wherein a cylindrical pressurized tank form an integral part of a superstructure for supporting one or more of such tanks in a motor vehicle.

(14) FIGS. 1A-8 of the disclosure illustrates aspects of the disclosed exemplary implementations of cooperating tank and sub-rack elements forming a rack superstructure.

(15) A rack module 10 forms a base element of a cooperating rack. The rack module 10 is a unit that both provide a pressurized fuel cylinder, mounting fixtures and is load bearing. A cylindrical composite fuel tank 15 with an input/output valve 16 is affixed to, or formed with, a series of bases.

(16) In some exemplary implementations the bases are positioned symmetrically around the tank's circumference at about 90 degree offsets. The bases must be of adequate size to allow vertical stacking without allowing the tanks 15 to touch.

(17) In some exemplary implementations the bases are positioned asymmetrically around the tank's circumference at about 90 degree offsets. The bases must be of adequate size to allow vertical stacking without allowing the tanks 15 to touch. However, with asymmetrical stacking the outer wall of the fuel tank OW may extend beyond the bases.

(18) Although the modules illustrated herein show four bases touch points between modules, those of ordinary skill in the art will recognize that it is within the scope of this disclosure to add additional bases and such an addition does not go beyond the scope of this disclosure. For a longer fuel tank or larger circumference fuel tank additional bases may be necessary to provide additional support for a vertical rack structure. Additionally, a greater number of smaller bases with less load-bearing capacity may be substituted for a few larger bases with greater load-bearing capacity.

(19) In some exemplary in implementations that bases are non-homogeneous. There are top bases 20 and bottom bases 30. The bottom of the tank can be affixed to four bottom bases: a front left bottom base 30A, a front bottom right base 30A, a back left bottom base 30B and a back right bottom base 30B. The top of the tank can be affixed to four top bases: a front left top base 20A, a front top right base 20A, a back top left base 20B, and a back top right base 20B. Each base has an interface 22 wherein the bases region at the interface corresponds to the curvature of the fuel tank. Each top base 20A, 20A, 20B, 20B has a head latch 25 extending. The head latch also has a pin guide 27 through which a top and bottom base may be connected. Each bottom base 30A, 30A, 30B, 30B has a head catch 35 forming a well into the base. Each bottom base 30A, 30A, 30B, 30B also has a pin guide 27 which passes through the catch 35, through which a top and bottom base may be connected.

(20) It is envisioned that the bases are preferably steel. However, those of ordinary skill in the art will recognize that in some instances composite, laminate or other materials with adequate strength may be substituted without depart form the scope of the invention.

(21) Bases must be affixed to tanks 15. Adhesive 40 is applied between the interface 22 and the fuel tank's outer wall OW. The adhesive should have the properties of high tensile strength and flexibility. It should operate over at least about 5 years and more preferably at least about 10 years. Most preferably the adhesive should operate within its nominal load bearing requirements for at least 15 years. The temperature range the adhesive should operate in is between 40 degrees Celsius and +85 degrees Celsius.

(22) When mounting a first module 10 to a second module 10 the head latches 25 are fitted and/or mated in to catches 35. A fastener 37 such as a pin, bolt or the like is inserted through the pin guides 27 and fixed in place.

(23) The fuel tank 15 has a diameter d.sup.tank, and when mounted to bases (forming a module) in the asymmetrical configuration the outer edge to edge distance of a top base 20 to a bottom base 30 (from 20A to 30A, 20A to 30A, 20B to 30B, and 20B to 30B) is d.sup.1. The outer edge to edge distance between two front bottom bases or two back bottom bases (30A to 30A, 30B to 30B) is d.sup.2. In an asymmetrical configuration d.sup.2 is less than d.sup.tank thereby minimizing footprint and space requirements to the tank. However in the distance between modules (and associated tanks) is defined by d.sup.1 which is greater than d.sup.tank thereby keeping the fuel tanks from contacting each other.

(24) A vertical rack is formed when two or more modules are attached. Unlike traditional racks which are unitary cage structures to which fuel tanks are secured and the tanks form no part of the superstructure, disclosed herein are modules which include the fuel tank and which are the superstructure of the rack. Shown in FIG. 7 is a two tier vertical rack 280 formed of two modules 10 and 10. The vertical mounting members 300 are fixtures to add the rack (which also includes the gaseous fuel) to a truck. Modules, at the bases, provide a substantially vertical interface 45 with mountings 310 to accept corresponding fasteners 315.

(25) Shown in FIG. 5 is a three tiered rack 350 formed of modules (10, 10, and 10). The strength of the rack is provided by cooperating module 10. Rather than affixed fuel tanks to a ridged frame structure which meets the NFPA 52 and/or other standards disclosed herein is a method and system of modules that cooperate to form the superstructure. The fuel tank is a sub-member of the module thereby reducing weight which in turn can reduce Tare weight of a truck using this system. Those of ordinary skill in the art will recognize that this arrangement is antithetical to a rigid superstructure rack to which fuel tanks are affixed.

(26) Force lines 500 and 501 illustrate how the cylindrical fuel tank 15 when affixed to top bases 20 and bottom bases 30 (a first module 10) supports the load of the next module(s) 10 and 10. The load supported by each module is directed through the module from each top front base to the opposing bottom front base, from 20A to 30A and from 20A to 30A, and from each top back base to the opposing bottom back base, from 20B to 30B and from 20B to 30B. The cylindrical tanks both carry fuel and are structural supports forming the rack 350. Each fuel tank 15 is cylindrical and preferably has a burst pressure of about 2.2 to 3 times its nominal psi rating. That burst pressure equates to a crush strength. If the nominal psi rating is 3000 psi the force needed to crush the tank will be between about 6600 psi and about 9000 psi. The strength of the tank is adequate to withstand a static force, applied in the six principal directions of eight times the weight of the fully pressurized container with a maximum displacement of 0.50 in.

(27) When affixing the rack 350 to a truck a vertical member 300 which is firmly mounted to the truck can be used. A series of isolators 50 formed of a rubber-like boundary layer to reduce friction of a mounted module against the vertical members 300 are interspaced between the bases (20/30) and the vertical members 300.

(28) Force zones 502 and 503 are another representation of the force at play whereby the hoop strength and crush parameters of the fuel tank over an area (zone) corresponding substantially to the footprint of each base is sufficient to support the above module(s) to counter a static force, applied in the six principal directions of eight times the weight of the fully pressurized container with a maximum displacement of 0.50 in.

(29) FIG. 6 illustrates the placement of the tank valve 16 in a two tier rack 280 affixed to a vertical support member 300. The tank valve has a bottom 17 and a top 18. To align the bottom 17 of the valve in a predetermine position it is necessary to affix the bases (20/30) wherein the orientation of the valve (clocking) is such that the bottom 17 will align with a set point A along the circumference of the module. To affix the modules to the vertical support fasteners 315 are inserted through guides in the vertical member 300 through the rubber-like isolator 50 and into the vertical interface 45 mountings 310. Those of ordinary skill in the art will recognize that this arrangement is antithetical to a rigid superstructure rack to which fuel tanks are affixed.

(30) FIGS. 7 and 8 illustrate an alternate base configuration wherein a unitary base 60 is used in lieu of the top and bottom bases. The unitary base can act as both a top and a bottom base. The base is adhered to the fuel tank 15 via an adhesive 40. The unitary base has three interfaces. An arc shaped interface 61 which corresponds to the curvature of a fuel tank and is configured to accept adhesive. Such configuration may include surface treatment, acid wash, ion etching, milling, chemical treatment, increased roughness, increased surface porosity and the like. The second interface is a base interface 62 whereby two bases are connected when adding modules to a vertical rack. The third interface is a truck mounting interface 63 whereby modules may be mounted to vertical elements for truck mounting. A support body 64 is provided integral to the bases and attached to the interfaces. A series of module mounting guides MMG 70 are provided along the base interface to allow for fastening of bases together with fasteners 75. A varies of truck mounting guides TMG 80 are provide along the truck mounting interfaces to allow the rack to be mounted to vertical members 300.

(31) Those of ordinary skill in the art will recognize that this arrangement is antithetical to a rigid superstructure rack to which fuel tanks are affixed.

(32) While the method and agent have been described in terms of what are presently considered to be the most practical and preferred implementations, it is to be understood that the disclosure need not be limited to the disclosed implementations. It is intended to cover various modifications and similar arrangements included within the spirit and scope of the claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structures. The present disclosure includes any and all implementations of the following claims.

(33) It should also be understood that a variety of changes may be made without departing from the essence of the disclosure. Such changes are also implicitly included in the description. They still fall within the scope of this disclosure. It should be understood that this disclosure is intended to yield a patent covering numerous aspects of the disclosure both independently and as an overall system and in both method and apparatus modes.

(34) Further, each of the various elements of the disclosure and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of an implementation of any apparatus implementation, a method or process implementation, or even merely a variation of any element of these.

(35) Particularly, it should be understood that as the disclosure relates to elements of the disclosure, the words for each element may be expressed by equivalent apparatus terms or method termseven if only the function or result is the same.

(36) Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this disclosure is entitled.

(37) It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action.

(38) Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates.

(39) Any patents, publications, or other references mentioned in this application for patent are hereby incorporated by reference. In addition, as to each term used it should be understood that unless its utilization in this application is inconsistent with such interpretation, common dictionary definitions should be understood as incorporated for each term and all definitions, alternative terms, and synonyms such as contained in at least one of a standard technical dictionary recognized by artisans and the Random House Webster's Unabridged Dictionary, latest edition are hereby incorporated by reference.

(40) Finally, all referenced listed in the Information Disclosure Statement or other information statement filed with the application are hereby appended and hereby incorporated by reference; however, as to each of the above, to the extent that such information or statements incorporated by reference might be considered inconsistent with the patenting of this/these disclosure(s), such statements are expressly not to be considered as made by the applicant(s).

(41) In this regard it should be understood that for practical reasons and so as to avoid adding potentially hundreds of claims, the applicant has presented claims with initial dependencies only.

(42) Support should be understood to exist to the degree required under new matter lawsincluding but not limited to United States Patent Law 35 USC 132 or other such lawsto permit the addition of any of the various dependencies or other elements presented under one independent claim or concept as dependencies or elements under any other independent claim or concept.

(43) To the extent that insubstantial substitutes are made, to the extent that the applicant did not in fact draft any claim so as to literally encompass any particular implementation, and to the extent otherwise applicable, the applicant should not be understood to have in any way intended to or actually relinquished such coverage as the applicant simply may not have been able to anticipate all eventualities; one skilled in the art, should not be reasonably expected to have drafted a claim that would have literally encompassed such alternative implementations.

(44) Further, the use of the transitional phrase comprising is used to maintain the open-end claims herein, according to traditional claim interpretation. Thus, unless the context requires otherwise, it should be understood that the term compromise or variations such as comprises or comprising, are intended to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

(45) Such terms should be interpreted in their most expansive forms so as to afford the applicant the broadest coverage legally permissible.