Compressed gas fuel storage system

An integrated compressed gas vehicle fuel storage system, comprising:

• a plurality of compressed gas pressure cells of the type incorporating domed ends and cylindrical bodies;
• a container for said plurality of compressed gas pressure cells;
• means for preventing the mechanical coupling of said compressed gas pressure cells or said container, said means for preventing comprising:
• shock absorbing means positioned in the ends of said container and dimensioned to cradle the said domed ends of said compressed gas pressure cells;
• and an elastomeric cap positioned between each of said domed ends and said shock absorbing means;
• and
• a gas control assembly pneumatically interconnecting said plurality of compressed gas pressure cells.

A vehicle fuel storage system, comprising:

• a pressure cell assembly comprised of a plurality of pressure cells, the pressure cells being fabricated by a filament winding process;
• a molded protective housing enclosing said pressure cell assembly, said molded protective housing dimensioned to conform to the shape of said pressure cell assembly;
• shock absorbing means for positioning said pressure cell assembly within said molded protective housing;
• an elastomeric cap positioned between each of said pressure cells and said shock absorbing means, said elastomeric cap and said shock absorbing means providing a radial air space about said pressure cells dimensioned to permit pressure induced expansion of said pressure cells and prevent physical contact there between;
• a gas control assembly to pneumatically connect said pressure cells;
• a protective cover for said gas control assembly;
• and
• means for securing said protective cover to said protective housing.

A process for making a vehicle fuel storage system, comprising the steps of:

• creating a molded upper integrated storage system outer shell half;
• creating a molded lower integrated storage system outer shell half;
• bonding pre-molded foam shock absorbing, pressure cell supporting bumpers into the upper and lower integrated storage system outer shell halves;
• bonding elastomeric caps to the domed ends of said pressure cells;
• enclosing a plurality of pressure cells between the upper and lower integrated storage system outer shell halves with the domed ends of the pressure cells within the foam shock absorbing bumpers;
• attaching a gas control assembly to the plurality of pressure cells;
• and
• attaching a gas control assembly cover to the upper and lower integrated storage system outer shell halves.

A process for making a vehicle fuel storage system, comprising the steps of:

• creating a molded upper integrated storage system outer shell half;
• creating a molded lower integrated storage system outer shell half;
• molding in-place foam shock absorbing, pressure cell supporting bumpers into the upper and lower integrated storage system outer shell halves;
• bonding elastomeric caps to the domed ends of said pressure cells;
• enclosing a plurality of pressure cells between the upper and lower integrated storage system outer shell halves with the domed ends of the pressure cells within the foam shock absorbing bumpers;
• attaching a gas control assembly to the plurality of pressure cells;
• and
• attaching a gas control assembly cover to the upper and lower integrated storage system outer shell halves.