Vehicle incorporating gas storage vessel comprising a polymeric container system for pressurized fluids

[0002] The present invention is directed to a vehicle incorporating a container system for pressurized fluids that is lightweight and flexible. The container system may be employed to store medicinal gas, e.g., oxygen, in an emergency medical vehicle, and/or the container can be employed to hold fuel sources stored under pressure.

[0003] Vehicles carrying containers for storing gases under pressure have widespread applications. For example, emergency medical vehicles (e.g. ambulances and emergency medical service vehicles) typically carry containers of medicinal gas (e.g. oxygen) under pressure. The gas carried on board the vehicle is used for administering the gas to a patient and/or for transfilling smaller, portable ambulatory containers to be used out of the immediate proximity of the vehicle.

[0004] Still other vehicles having internal combustion engines carry containers of pressurized, combustible gas (e.g. hydrogen, propane, natural gas) as a fuel source for the engine. Such gas burning engines can be found in, for example, inner city buses and indoor utility vehicles, for example, fork lifts, in which the combustion exhausts of a conventional gasoline engine are undesirable, unhealthy, or unsafe.

[0005] Onboard supplies of pressurized gas for vehicles have conventionally been provided by pressure vessels in the form of metal canisters. Such canisters are heavy and bulky, thus adding significant weight to the vehicle and taking up a substantial amount of space. Furthermore, such metal canisters, especially when filled with a gas under pressure, can be inherently unsafe. For example, the canisters can become dislodged during a collision in which case the canister itself, which may weigh 300-500 lbs., can become a flying projectile, or the canister can rupture or become punctured which can cause an explosion resulting in fragmentation of the canister.

[0006] Container systems made from lightweight synthetic materials have been proposed. Scholley, in U.S. Pat. Nos. 4,932,403; 5,036,845; and 5,127,399, describes a flexible and portable container for compressed gases which comprises a series of elongated, substantially cylindrical chambers arranged in a parallel configuration and interconnected by narrow, bent conduits and attached to the back of a vest that can be worn by a person. The container includes a liner, which may be formed of a synthetic material such as nylon, polyethylene, polypropylene, polyurethane, tetrafluoroethylene, or polyester. The liner is covered with a high-strength reinforcing fiber, such as a high-strength braid or winding of a reinforcing material such as KEVLAR® aramid fiber, and a protective coating of a material, such as polyurethane, covers the reinforcing fiber.

[0007] The design described in the Scholley patents suffers a number of shortcomings which makes it impractical for use as a container for fluids stored at the pressure levels typically seen in portable fluid delivery systems such as SCUBA gear, firefighter's oxygen systems, emergency oxygen systems, and medicinal oxygen systems. The elongated, generally cylindrical shape of the separate storage chambers does not provide an effective structure for containing highly-pressurized fluids. Also, the relatively large volume of the storage sections creates an unsafe system subject to possible violent rupture due to the kinetic energy of the relatively large volume of pressurized fluid stored in each chamber.

[0008] Accordingly, there is a need for improved container systems made of light weight polymeric material and which are robust and less susceptible to violent rupture and can be easily incorporated onto a vehicle without adding significant weight or bulk.

[0009] In accordance with aspects of the present invention, a transport vehicle comprises a vehicle body supported on wheels and defining a vehicle interior compartment and a gas storage pack carried on the vehicle body for providing a portable supply of a gas stored in the gas storage pack. The gas storage pack includes a pressure vessel which comprises a plurality of hollow chambers, each having a substantially spherical or ellipsoidal shape, a plurality of relatively narrow conduit sections, each positioned between adjacent hollow chambers to interconnect the hollow chambers, and a reinforcing filament wrapped around the hollow chambers and conduit sections. The gas storage pack further includes a gas transfer control system attached to the pressure vessel and constructed and arranged to control flow of gas into and out of the pressure vessel.

[0010] In accordance with other aspects of the present invention, a motorized vehicle comprises a vehicle frame, a motor carried on the frame for driving the vehicle, and a gas storage pack carried on the frame for providing a portable supply of gas under pressure as a fuel source for the motor. The gas storage pack includes a pressure vessel which comprises a plurality of hollow chambers, each having a substantially spherical or ellipsoidal shape, a plurality of relatively narrow conduit sections, each positioned between adjacent hollow chambers to interconnect the hollow chambers, and a reinforcing filament wrapped around the hollow chambers and conduit sections. The gas storage pack further includes a gas transfer control system attached to the pressure vessel and constructed and arranged to control flow of gas into and out of the pressure vessel.

[0011] Other objects, features, and characteristics of the present invention will become apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of the specification, and wherein like reference numerals designate corresponding parts in the various figures.

[0012] FIG. 1 is a broken side elevational view of a plurality of aligned, rigid, generally ellipsoidal chambers interconnected by a tubular core.

[0013] FIG. 2 is an enlarged horizontal sectional view taken along the line 2—2 in FIG. 1.

[0014] FIG. 2A is an enlarged horizontal sectional view taken along the line 2—2 in FIG. 1 showing an alternate embodiment.

[0015] FIG. 3 is a side elevational view of a portion of a container system of the present invention.

[0016] FIG. 4 is a partial longitudinal sectional view along line 4—4 in FIG. 3.

[0017] FIG. 5 is a side elevational view of an alternative embodiment of the container system of the present invention.

[0018] FIG. 5A is a partial view of the container system of FIG. 5 arranged in a sinuous configuration.

[0019] FIG. 6 is a portable pressurized fluid pack employing a container system according to the present invention.

[0020] FIG. 7 is an alternate embodiment of a pressurized fluid pack employing the container system of the present invention.

[0021] FIG. 8 is still another alternate embodiment of a pressurized fluid pack employing a container system according to the present invention.

[0022] FIG. 9 is a plan view of a container system according to the present invention secured within a conforming shell of a housing for a portable pressurized fluid pack.

[0023] FIG. 9A is a transverse section along the line 9—9 in FIG. 9.

[0024] FIG. 10 is a partial, exploded view in longitudinal section of a system for securing a polymeric tube to a mechanical fitting.

[0025] FIG. 11 is perspective view of a transport vehicle having a container system comprised of discreet interconnected chambers incorporated thereon in accordance with the present invention.

[0026] FIG. 12 is partial perspective top view of a gas storage pack carried on a roof panel of a vehicle.

[0027] FIG. 13 is a perspective view of a columnar gas storage pack constructed in accordance with the present invention.

[0028] FIG. 14 is a solid rectangular gas storage pack constructed in accordance with the present invention.

[0029] FIG. 15 is side elevation of a motorized utility vehicle having mounted thereon a gas storage pack including a pressure vessel comprising interconnected hollow chambers in accordance with the present invention.

[0030] With reference to the figures, exemplary embodiments of the invention will now be described. These embodiments illustrate principles of the invention and should not be construed as limiting the scope of the invention.

[0031] As shown in FIGS. 1 and 2, U.S. Pat. No. 6,047,860 (the disclosure of which is hereby incorporated by reference) to Sanders, an inventor of the present invention, discloses a container system 10 for pressurized fluids including a plurality of form-retaining, generally ellipsoidal chambers C interconnected by a tubular core T. The tubular core extends through each of the plurality of chambers and is sealingly secured to each chamber. A plurality of longitudinally-spaced apertures A are formed along the length of the tubular core, one such aperture being disposed in the interior space 20 of each of the interconnected chambers so as to permit infusion of fluid to the interior space 20 during filling and effusion of the fluid from the interior space 20 during fluid delivery or transfer to another container. The apertures are sized so as to control the rate of evacuation of pressurized fluid from the chambers. Accordingly, a low fluid evacuation rate can be achieved so as to avoid a large and potentially dangerous burst of kinetic energy should one or more of the chambers be punctured (i.e., penetrated by an outside force) or rupture.

[0032] The size of the apertures A will depend upon various parameters, such as the volume and viscosity of fluid being contained, the anticipated pressure range, and the desired flow rate. In general, smaller diameters will be selected for gasses as opposed to liquids. Thus, the aperture size may generally vary from about 0.010 to 0.125 inches. Although only a single aperture A is shown in FIG. 2, more than one aperture A can be formed in the tube T within the interior space 20 of the shell 24. In addition, each aperture A can be formed in only one side of the tube T, or the aperture A may extend through the tube T.

[0033] Referring to FIG. 2, each chamber C includes a generally ellipsoidal shell 24 molded of a suitable synthetic plastic material and having open front and rear ends 26 and 28. The diameters of the holes 26 and 28 are dimensioned so as to snugly receive the outside diameter of the tubular core T. The tubular core T is attached to the shells 24 so as to form a fluid tight seal therebetween. The tubular core T is preferably bonded to the shells 24 by means of light, thermal, or ultrasonic energy, including techniques such as, ultrasonic welding, radio frequency energy, vulcanization, or other thermal processes capable of achieving seam less circumferential welding. The shells 24 may be bonded to the tubular core T by suitable ultraviolet light-curable adhesives, such as 3311 and 3341 Light Cure Acrylic Adhesives available from Loctite Corporation, having authorized distributors throughout the world. The exterior of the shells 24 and the increments of tubular core T between such shells are wrapped with suitable reinforcing filaments 30 to increase the hoop strength of the chambers C and tubular core T and thereby resist bursting of the shells and tubular core. A protective synthetic plastic coating 32 is applied to the exterior of the filament wrapped shells and tubular core T.

[0034] More particularly, the shells 24 may be either roto molded, blow molded, or injection molded of a synthetic plastic material such as TEFLON® or fluorinated ethylene propylene. Preferably, the tubular core T will be formed of the same material. The reinforcing filaments 30 may be made of a carbon fiber, KEVLAR® or nylon. The protective coating 32 may be made of urethane to protect the chambers and tubular core against abrasions, UV rays, moisture, or thermal elements. The assembly of a plurality of generally ellipsoidal chambers C and their supporting tubular core T can be made in continuous strands of desired length. In the context of the present disclosure, unless stated otherwise, the term “strand” will refer to a discrete length of interconnected chambers.

[0035] As shown in FIG. 2A, the tube T can be co-formed, such as by co-extrusion, along with shells 24′ and tubular portions T′ integrally formed with the shells 24′ and which directly overlie the tube T between adjacent shells 24′. Furthermore, as also shown in FIG. 2A, more than one aperture A may be formed in the tube T within the interior 20 of the shell 24′. The co-formed assembly comprised of the shells 24′, tubular portions T′, and tube T can be wrapped with a layer of reinforcing filaments 30 and covered with a protective coating 32 as described above.

[0036] The inlet or front end of the tubular core T may be provided with a suitable threaded male fitting 34. The discharge or rear end of a tubular core T may be provided with a threaded female fitting 36. Such male and female fittings provide a pressure-type connection between contiguous strands of assemblies of chambers C interconnected by tubular cores T and provide a mechanism by which other components, such as gauges and valves, can be attached to the interconnected chambers. A preferred structure for attaching such fittings is described below.

[0037] A portion of a pressure vessel constructed in accordance with principles of the present invention is designated generally by reference number 40 in FIG. 3. The pressure vessel 40 includes a plurality of fluid storage chambers 50 having a preferred ellipsoidal shape and having hollow interiors 54. The individual chambers 50 are pneumatically interconnected with each other by connecting conduit sections 52 and 56 disposed between adjacent ones of the chambers 50. Conduit sections 56 are generally longer than the conduit sections 52. The purpose of the differing lengths of the conduit sections 52 and 56 will be described in more detail below.

[0038] FIG. 4 shows an enlarged longitudinal section of a single hollow chamber 50 and portions of adjacent conduit sections 52 of the pressure vessel 40. The pressure vessel 40 preferably has a layered construction including polymeric hollow shells 42 with polymeric connecting conduits 44 extended from opposed open ends of the shells 42. The pressure vessel 40 includes no tubular core, such as tubular core T shown in FIGS. 2 and 2A, extending through the hollow shells 42.

[0039] The polymeric shells 42 and the polymeric connecting conduits 44 are pre ferably formed from a synthetic plastic material such as TEFLON® or fluorinated ethylene propylene and may be formed by any of a number of known plastic-forming techniques such as extrusion, roto molding, chain blow molding, or injection molding.

[0040] Materials used for forming the shells 42 and connecting conduits 44 are preferably moldable and exhibit high tensile strength and tear resistance. Most preferably, the polymeric hollow shells 42 and the polymeric connecting conduits 44 are formed from a thermoplastic polyurethane elastomer manufactured by Dow Plastics under the name PELLETHANE® 2363-90AE, a thermoplastic polyurethane elastomer manufactured by the Bayer Corporation, Plastics Division under the name TEXIN® 5286, a flexible polyester manufactured by Dupont under the name HYTREL®, or polyvinyl chloride from Teknor Apex.

[0041] In a preferred configuration, the volume of the hollow interior 54 of each chamber 50 is within a range of capacities configurable for different applications, with a most preferred volume of about thirty (30) milliliters. It is not necessary that each chamber have the same dimensions or have the same capacity. It has been determined that a pressure vessel 40 having a construction as will be described below will undergo a volume expansion of 7-10% when subjected to an internal pressure of 2000 psi. In a preferred configuration, the polymeric shells 42 each have a longitudinal length of about 3.0-3.5 inches, with a most preferred length of 3.250-3.330 inches, and a maximum outside diameter of about 0.800 to 1.200 inches, with a most preferred diameter of 0.095-1.050 inches. The conduits 44 have an inside diameter D₂preferably ranging from 0.125-0.300 inches with a most preferred range of about 0.175-0.250 inches. The hollow shells 42 have a typical wall thickness ranging from 0.03 to 0.05 inches with a most preferred typical thickness of about 0.04 inches. The connecting conduits 44 have a wall thickness ranging from 0.03 to 0.10 inches and preferably have a typical wall thickness of about 0.040 inches, but, due to the differing amounts of expansion experienced in the hollow shells 42 and the conduits 44 during a blow molding forming process, the conduits 44 may actually have a typical wall thickness of about 0.088 inches.

[0042] The exterior surface of the polymeric hollow shells 42 and the polymeric connecting conduits 44 is preferably wrapped with a suitable reinforcing filament fiber 46. Filament layer 46 may be either a winding or a braid (preferably a triaxial braid pattern having a nominal braid angle of 75 degrees) and is preferably a high-strength aramid fiber material such as KEVLAR® (preferably 1420 denier fibers), carbon fibers, or nylon, with KEVLAR® being most preferred. Other potentially suitable filament fiber material may include thin metal wire, glass, polyester, or graphite. The KEVLAR® winding layer has a preferred thickness of about 0.035 to 0.055 inches, with a thickness of about 0.045 inches being most preferred.

[0043] A protective coating 48 may be applied over the layer of filament fiber 46. The protective coating 48 protects the shells 42, conduits 44, and the filament fiber 46 from abrasions, UV rays, thermal elements, or moisture. Protective coating 32 is preferably a sprayed-on synthetic plastic coating. Suitable materials include polyvinyl chloride and polyurethane. The protective coating 32 may be applied to the entire pressure vessel 40, or only to more vulnerable portions thereof. Alternatively, the protective coating 32 could be dispensed with altogether if the pressure vessel 40 is encased in a protective, moisture-impervious housing.

[0044] The inside diameter D₁of the hollow shell 42 is preferably much greater than the inside diameter D₂of the conduit section 44, thereby defining a relatively discrete storage chamber within the hollow interior 54 of each polymeric shell 42. This serves as a mechanism for reducing the kinetic energy released upon the rupturing of one of the chambers 50 of the pressure vessel 40. That is, if one of the chambers 50 should rupture, the volume of pressurized fluid within that particular chamber would escape immediately. Pressurized fluid in the remaining chambers would also move toward the rupture, but the kinetic energy of the escape of the fluid in the remaining chambers would be regulated by the relatively narrow conduit sections 44 through which the fluid must flow on its way to the ruptured chamber. Accordingly, immediate release of the entire content of the pressure vessel is avoided.

[0045] An alternate pressure vessel 40′ is shown in FIGS. 5 and 5A. Pressure vessel 40′ includes a plurality of hollow chambers 50′ having a generally spherical shape connected by conduit sections 52′ and 56′. As shown in FIG. 5A, one particular configuration of the pressure vessel 40′ is to bend it back-and-forth upon itself in a sinuous fashion. The pressure vessel 40′ is bent at the elongated conduit sections 56′, which are elongated relative to the conduit sections 52′ so that they can be bent without kinking or without adjacent hollow chambers 50′ interfering with each other. Accordingly, the length of the conduit sections 56′ can be defined so as to permit the pressure vessel to be bent thereat without kinking and without adjacent hollow chambers 50′ interfering with each other. In general, a connecting conduit section 56′ of sufficient length can be provided by omitting a chamber 50′ in the interconnected series of chambers 50′. The length of a long conduit section 56′, however, need not necessarily be as long as the length of a single chamber 50′.

[0046] Both ellipsoidal and the spherical chambers are preferred, because such shapes are better suited than other shapes, such as cylinders, to withstand high internal pressures. Spherical chambers 50′ are not, however, as preferable as the generally ellipsoidal chambers 50 of FIGS. 3 and 4, because, the more rounded a surface is, the more difficult it is to apply a consistent winding of reinforcing filament fiber. Filament fibers, being applied with axial tension, are more prone to slipping on highly rounded, convex surfaces.

[0047] A portable gas storage pack 60 employing a pressure vessel 40 as described above is shown in FIG. 6. Note that the gas storage pack 60 includes a pressure vessel 40 having generally ellipsoidal hollow chambers 50. It should be understood, however, that a pressure vessel 40 of a type having generally spherical hollow chambers as shown in FIGS. 5 and 5A could be employed in the gas storage pack 60 as well. The pressure vessel 40 is arranged as a continuous, serial strand 58 of interconnected chambers 50 bent back-and-forth upon itself in a sinuous fashion with all of the chambers lying generally in a common plane. In general, the axial arrangement of any strand of interconnected chambers can be an orientation in any angle in X-Y-Z Cartesian space. Note again, in FIG. 6, that elongated conduit sections 56 are provided. Sections 56 are substantially longer than conduit sections 52 and are provided to permit the pressure vessel 40 to be bent back upon itself without kinking the conduit section 56 or without adjacent chambers 50 interfering with one another. Again, an interconnecting conduit 56 of sufficient length for bending can be provided by omitting a chamber 50 from the strand 58 of interconnected chambers.

[0048] The pressure vessel 40 is encased in a protective housing 62. Housing 62 may have a handle, such as an opening 64, provided therein.

[0049] A fluid transfer control system 76 is pneumatically connected to the pressure vessel 40 and is operable to control transfer of fluid under pressure into or out of the pressure vessel 40. In the embodiment illustrated in FIG. 6, the fluid transfer control system includes a one-way inlet valve 70 (also known as a fill valve) pneumatically connected (e.g., by a crimp or swage) to a first end 72 of the strand 58 and a one-way outlet valve/regulator 66 pneumatically connected (e.g., by a crimp or swage) to a second end 74 of the pressure vessel 40. In general, the inlet valve 70 includes a mechanism permitting fluid to be transferred from a pressurized fluid fill source into the pressure vessel 40 through inlet valve 70 and to prevent fluid within the pressure vessel 40 from escaping through the inlet valve 70. Any suitable one-way inlet valve, well known to those of ordinary skill in the art, may be used.

[0050] The outlet valve/regulator 66 generally includes a well known mechanism permitting the outlet valve/regulator to be selectively configured to either prevent fluid within the pressure vessel 40 from escaping the vessel through the valve 66 or to permit fluid within the pressure vessel 40 to escape the vessel in a controlled manner through the valve 66. Preferably, the outlet valve/regulator 66 is operable to “step down” the pressure of fluid exiting the pressure vessel 40. For example, in typical medicinal applications of ambulatory oxygen, oxygen may be stored within the tank at up to 3,000 psi, and a regulator is provided to step down the outlet pressure to 20 to 50 psi. The outlet valve/regulator 66 may include a manually-operable control knob 68 for permitting manual control of a flow rate therefrom. Any suitable regulator valve, well known to those of ordinary skill in the art, may be used.

[0051] A pressure relief valve (not shown) is preferably provided to accommodate internal pressure fluctuations due to thermal cycling or other causes.

[0052] In FIG. 6, the pressure vessel 40, inlet valve 70, and the outlet valve/regulator 66 are shown exposed on top of the housing 62. Preferably, the housing comprises dual halves of, for example, preformed foam shells as will be described in more detail below. For the purposes of illustrating the structure of the embodiment of FIG. 6, however, a top half of the housing 62 is not shown. It should be understood, however, that a housing would substantially encase the pressure vessel 40 and at least portions of the outlet valve/regulator 66 and the inlet valve 70.

[0053] FIG. 7 shows an alternate embodiment of a portable gas storage pack generally designated by reference number 80. The gas storage pack 80 includes a pressure vessel formed by a number of strands 92 of individual chambers 94 serially interconnected by interconnecting conduit sections 96 and arrange generally in parallel to each other. In the embodiment illustrated in FIG. 7, the pressure vessel includes six individual strands 92, but the gas storage pack may include fewer than or more than six strands.

[0054] Each of the strands 92 has a first closed end 98 at the endmost of the chambers 94 of the strand 92 and an open terminal end 100 attached to a coupling structure defining an inner plenum, which, in the illustrated embodiment, comprises a distributor 102. The distributor 102 includes an elongated, generally hollow body 101 defining the inner plenum therein. Each of the strands 92 of interconnected chambers is pneumatically connected at its respective terminal end 100 by a connecting nipple 104 extending from the elongated body 101, so that each strand 92 of interconnected chambers 94 is in pneumatic communication with the inner plenum inside the distributor 102. Each strand 92 may be connected to the distributor 102 by a threaded interconnection, a crimp, or a swage, or any other suitable means for connecting a high pressure polymeric tube to a rigid fitting. A fluid transfer control system 86 is pneumatically connected to the distributor 102. In the illustrated embodiment, the fluid transfer control system 86 includes a one-way inlet valve 88 and a one-way outlet/regulator 90 pneumatically connected at generally opposite ends of the body 101 of the distributor 102.

[0055] The strands 92 of interconnected chambers 94, the distributor 102, and at least portions of the inlet valve 88 and the outlet valve/regulator 90 are encased within a housing 82, which may include a handle 84, as illustrated in FIG. 7, to facilitate carrying of the gas storage pack 80.

[0056] In FIG. 8 is shown still another alternative embodiment of a gas storage pack generally designated by reference number 110. The gas storage pack 110 includes a pressure vessel comprised of a number of generally parallel strands 120 of hollow chambers 122 serially interconnected by interconnecting conduit sections 124. Each of the strands 120 has a closed end 126 at the endmost of its chambers 122 and an open terminal end 128 attached to a coupling structure defining an inner plenum. In the illustrated embodiment, the coupling structure comprises a manifold 118 to which is pneumatically attached each of the respective terminal ends 128 of the strands 120. Each strand 120 may be connected to the manifold 118 by a threaded interconnection, a crimp, or a swage, or any other suitable means for connecting a high pressure polymeric tube to a rigid fitting. A fluid transfer control system 116 is attached to the manifold 118, and, in the illustrated embodiment, comprises a outlet valve/regulator 90 and an inlet valve (not shown).

[0057] The hollow chambers of the pressure vessels described above and shown in FIGS. 5A, 6, 7, and 8 can be of the type shown in FIGS. 2 and 2A having an internal perforated tubular core, or they can be of the type shown in FIG. 4 having no internal tubular core.

[0058] FIGS. 9 and 9A show one-half of a foam shell, generally indicated at 164, for encasing a pressure vessel 144 to form a housing for a portable gas storage pack. The pressure vessel 144 shown in FIG. 9 includes a sinuous arrangement of generally spherical chambers 146 serially interconnected by short interconnecting conduit sections 148 and longer, bendable interconnecting conduit sections 150. The foam shell 164 is preferably a molded synthetic foam “egg crate” design. That is, the shell 164 includes a plurality of chamber recesses 154 serially interconnected by short, straight interconnecting channels 156 and long, curved interconnecting channels 158. The chamber recesses 154 and the interconnecting channels 156 and 158 are arranged in the preferred arrangement of the chambers 146 and interconnecting conduits 148 and 150 of the pressure vessel 144. Alternatively, the chamber recesses 154 and interconnecting channels 156, 158 could be configured in other preferred arrangements such as, for example, those arrangements shown in FIGS. 6, 7, and 8.

[0059] The foam shell 164 may be formed from neoprene padding or a polyurethane-based foam. Most preferably, the foam shell is formed from a closed cell, skinned foam having a liquid impervious protective skin layer. Suitable materials include polyethylene, polyvinyl chloride, and polyurethane. The use of a self-skinning, liquid impervious foam may eliminate the need for the protective synthetic plastic coating 48 (see FIG. 4) applied directly onto the reinforcing filament layer. A fire retardant additive, such as, for example, fire retardant additives available from Dow Chemical, can be added to the foam material of the foam shells.

[0060] A second foam shell (not shown) has chamber recesses and interconnecting channels arranged in a configuration that registers with the chamber recesses 154 and the interconnecting channels 156 and 158 of the foam shell 164. The two foam shells are arranged in mutually-facing relation and closed upon one another to encase the pressure vessel 144. The mating foam shells are thereafter adhesively-attached to one another at marginal edge portions thereof.

[0061] Suitable adhesives for attaching the mating foam shell halves include pressure sensitive adhesives.

[0062] FIG. 10 shows a preferred arrangement for attaching a mechanical fitting 260 to a polymeric tube 262 in a manner that can withstand high pressures within the tube 262. Such fittings 260 can be attached to the ends of a continuous strand of serially connected hollow chambers for connecting inlet and outlet valves at the opposite ends. For example, fittings 34 and 36 shown in FIG. 1 could be attached in the manner to be described. The mechanical fitting 260 has a body portion, which, in the illustrated embodiment includes a threaded end 264 to which can be attached another component, such as a valve or a gauge, and a faceted portion 266 that can be engaged by a tool such as a wrench. The body portion is preferably made of brass. End 264 is shown as an exteriorly threaded male connector portion, but could be an interiorly threaded female connector portion. An exteriorly threaded collar 268 extends to the right of the faceted portion 266. An inserting projection 270 extends from the threaded collar 268 and has formed thereon a series of barbs 272 of the “Christmas tree” or corrugated type that, due to the angle of each of the barbs 272, permits the projection 270 to be inserted into the polymeric tube 262, as shown, but resists removal of the projection 270 from the polymeric tube 262. A channel 274 extends through the entire mechanical fitting 260 to permit fluid transfer communication through the fitting 260 into a pressure vessel.

[0063] A connecting ferrule 280 has a generally hollow, cylindrical shape and has an interiorly threaded opening 282 formed at one end thereof. The remainder of the ferrule extending to the right of the threaded opening 282 is a crimping portion 286. The ferrule 280 is preferably made of 6061 T6 aluminum. The crimping portion 286 has internally-formed ridges 288 and grooves 284. The inside diameter of the ridges 288 in an uncrimped ferrule 280 is preferably greater than the outside diameter of the polymeric tube 262 to permit the uncrimped ferrule to be installed over the tube.

[0064] Attachment of the fitting 260 to the tube 262 is affected by first screwing the threaded collar 268 into the threaded opening 282 of the ferrule 280. Alternatively, the ferrule 280 can be connected to the fitting 260 by other means. For example, the ferrule 280 may be secured to the fitting 260 by a twist and lock arrangement or by welding (or soldering or brazing) the ferrule 280 to the fitting 260. The polymeric tube 262 is then inserted over the inserting projection 270 and into a space between the crimping portion 286 and the inserting projection 270. The crimping portion 286 is then crimped, or swaged, radially inwardly in a known manner to thereby urge the barbs 272 and the ridges 288 and grooves 284 into locking deforming engagement with the tube 262. Accordingly, the tube 262 is securely held to the fitting 260 by both the frictional engagement of the tube 262 with the barbs 272 of the inserting projection 270 as well as the frictional engagement of the tube 262 with the grooves 284 and ridges 288 of the ferrule 280, which itself is secured to the fitting 260, e.g., by threaded engagement of threaded collar 268 with threaded opening 282.

[0065] A connecting arrangement of the type shown in FIG. 10 could also be used, for example, for attaching the strands 92 of interconnected chambers to the connecting nipples 104 of the distributor 102 in FIG. 7 or to attach the strands of interconnected chambers 120 to the connecting nipples 138 and 140 of the manifold 118 of FIG. 8.

[0066] A transport vehicle having incorporated thereon a gas storage pack including a pressure vessel constructed in accordance with the present invention is generally indicated at reference number 300 in FIGS. 11 and 12. The transport vehicle 300, which, in the illustrated embodiment, is an ambulance van, includes a vehicle body 302 comprised of a floor panel 304, a roof panel 306 and wall panels 308 extending between the floor panel 304 and the roof panel 306. The vehicle 300 is supported on conventional tires, although the present invention is not limited to wheeled vehicles. A gas storage pack 310 is carried on the roof panel 306. The gas storage pack 310 includes a pressure vessel 312 comprising a plurality of hollow chambers 314 which are preferably ellipsoidal, but may be spherical in shape, interconnected by a plurality of narrow conduits 316 as described above. As also described above, the chambers 314 and conduits 316, which are preferably made of a polymer, are covered with a reinforcing filament layer and may be further coated with a liquid impervious protective coating. The chambers 314 may be of the type shown in FIGS. 2 and 2A and described above as having an inner tubular core with a series of longitudinally spaced apertures formed therein, or they may be of the type shown in FIG. 4, in which the tubular core is omitted.

[0067] The pressure vessel 312, which may comprise a continuous strand of interconnected chambers sinuously arranged throughout the pressure pack 310 or it may comprise a plurality of individual lengths of interconnected chambers, each length being connected to a common plenum or manifold, is preferably encased in a protective housing and would not be exposed as shown in the figures. Furthermore, the pressure pack 310 may also include a foam core 324, of the type described above, substantially surrounding the chambers 314 and the conduit sections 316.

[0068] The pressure pack 310 also includes a gas transfer control system 318 generally comprising a one-way inlet valve 320 which functions as described above, and an outlet valve/regulator 322 which also functions as described above. Either or both of the inlet valve 320 and the outlet valve/regulator 322 may be located interiorly of the vehicle, and it is preferred that the outlet valve 322 be located interiorly of the vehicle if interior access to the gas supply is desirable.

[0069] Gas storage pack configurations are shown in FIGS. 13 and 14. The gas storage pack of FIG. 13 is a columnar pack 328 in which the chambers 14 interconnected by conduits 316 are wound spirally around an axial line of symmetry 330 extending through the column. The columnar pack 328 can be circular or oval in cross-sectional shape and is so designed so that it can fit into conventional holding racks for metal canister pressure vessels. In FIG. 14 the pressure pack 326 is rectangular, such a shape being suitable for attaching the pack 326 to a vehicular panel and, in particular for attaching the pack beneath the vehicle.

[0070] Referring to FIG. 15, a motorized vehicle is generally indicated by reference number 340. In the illustration, vehicle 340 is a forklift. The vehicle includes a vehicle frame 342, and in the illustrated embodiment, the forklift includes wheels 344, an operator's seat 346, a steering wheel 348, and a fork 350. The vehicle 340 includes a motor schematically represented by the dashed rectangle indicated by reference number 352. Motor 352 is preferably an internal combustion engine. The various controls and power transmitting elements that would normally be associated with a vehicle having a motor are not shown, but would be readily appreciated and known by those of ordinary skill in the art. The motor 352 runs on a fuel comprising a combustible gas, for example, hydrogen, propane, or natural gas. A gas storage pack 354 constructed in accordance with the present invention is carried on the vehicle frame 342. The gas storage pack 354 includes a pressure vessel 356 constructed of hollow chambers 358 interconnected by conduit sections 360. As described above, the chambers may be ellipsoidal or spherical and are preferably made of a polymer, as are the conduits 360. Furthermore, the chambers 358 and conduits 360 are covered with a reinforcing fiber layer. Moreover, the chambers 358 may be of the type shown in FIGS. 2 and 2A having an internal tubular core, or they may be of the type shown in FIG. 4 in which the tubular core is omitted. The gas storage pack 354 also includes a gas transfer control system 362 having a one-way inlet valve 364 and an outlet valve/regulator 366, which function as described above. The storage pack 354 may also include a foam core 368 substantially surrounding the chambers 358 and conduits 360.

[0071] While the invention has been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but, on the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. Thus, it is to be understood that variations in the particular parameters used in defining the present invention can be made without departing from the novel aspects of this invention as defined in the following claims.