Systems and methods for fuel storage and delivery

Abstract

The present disclosure provides a pressurized fuel storage and delivery system comprising a tank with interior surfaces defining a fuel storage volume, a flexible bladder within the tank configured to contain fuel, a gas reservoir within the tank configured to store pressurized gas, a micro-perforated separator between the gas reservoir and bladder configured to allow controlled gas flow to a space surrounding the bladder. In some cases, microchannels on the tank interior surfaces or bladder exterior surface are configured to distribute pressurized gas around the bladder to control compression patterns and manage thermal effects during gas expansion. The system further includes pressurization port connected to the gas reservoir configured to introduce pressurized gas, and a fuel port connected to the bladder configured to allow fuel delivery when pressurized gas compresses the bladder.

Description

Systems and Methods for Fuel Storage and DeliveryCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application is a PCT international application that claims the benefit of U.S. Provisional Application No. 63 / 710,140, filed October 22, 2024, entitled “Pressurized Fuel Apparatus.”

[0002] The contents of each of the above referenced applications are hereby incorporated by reference in their entirety.TECHNICAL FIELD

[0003] Various aspects of the present disclosure relate generally to systems and methods for fuel storage and delivery and, more particularly, to fuel storage and delivery using microchannels, torus bladder, or safety features.BACKGROUND

[0004] Fuel storage and delivery systems are fundamental components in various applications ranging from aerospace and aviation to industrial and automotive systems. These systems face numerous challenges in providing reliable, efficient, and safe fuel delivery under diverse operating conditions.

[0005] Traditional fuel systems often rely on mechanical pumps, gravity-fed mechanisms, or complex fuel management systems to deliver fuel from storage tanks to engines or combustion chambers. However, these conventional approaches can encounter difficulties in extreme environments, such as high-acceleration conditions, variable orientations, or situations where electrical power may be limited or unavailable. Mechanical pumps, while effective in many applications, introduce additional complexity, maintenance requirements, and potential failure points that can compromise system reliability.

[0006] Fuel delivery systems also face challenges related to fuel contamination, where exposure to external elements or tank materials can degrade fuel quality over time. Additionally, conventional rigid fuel tanks may leave unusable fuel residuals due to pump pickup limitations or tank geometry constraints, reducing overall fuel utilization efficiency.

[0007] In applications involving extreme operating conditions, such as high-G environments or rapid orientation changes, traditional fuel systems may experience fuel starvation or inconsistent delivery rates. Fuel sloshing within tanks can create stability issues and unpredictable fuel flow characteristics, particularly in mobile applications where the fuel system experiences dynamic motion.

[0008] Temperature management presents another challenge in fuel storage systems. Rapid temperature changes, whether from environmental conditions or system operations, can affect fuel properties and system component integrity. Localized heating or cooling effects can create thermal stresses that may compromise system performance or component longevity.

[0009] Safety considerations in pressurized fuel systems include the management of high-pressure gases and the prevention of over-pressurization conditions that could lead to system failure. Conventional safety mechanisms may not provide adequate protection or may be difficult to reset after activation, limiting system reusability.

[0010] There exists a general need for fuel storage and delivery systems that can operate reliably across a wide range of conditions while minimizing complexity, maintenance requirements, and safety risks. Such systems would benefit from improved fuel utilization efficiency, enhanced thermal management capabilities, and robust safety features that maintain system integrity under various operating scenarios.

[0011] The present disclosure is directed to overcoming one or more of these abovereferenced challenges.SUMMARY OF THE DISCLOSURE

[0012] According to certain aspects of the disclosure, systems, methods, and computer readable memory are disclosed for pressurized fuel apparatus.

[0013] In some cases, a pressurized fuel storage and delivery system may include: a tank having interior surfaces defining a fuel storage volume; a flexible bladder positioned within the tank and configured to contain fuel; a gas reservoir positioned within the tank and configured to store pressurized gas; a micro-perforated separator positioned between the gas reservoir and the bladder, the micro-perforated separator configured to allow controlled gas flow from the gas reservoir to a space surroundingthe bladder; microchannels formed on at least one surface selected from the group consisting of the interior surfaces of the tank and an exterior surface of the bladder, the microchannels configured to distribute the pressurized gas around the bladder to control bladder compression patterns and manage thermal effects during gas expansion; a pressurization port connected to the gas reservoir and configured to introduce pressurized gas into the gas reservoir; and a fuel port connected to the bladder and configured to allow fuel delivery from the bladder when the pressurized gas compresses the bladder.

[0014] In some cases, a fuel storage and delivery apparatus may incude: a rigid tank configured to contain pressurized components; a flexible bladder positioned within the tank and configured to store liquid fuel, the bladder being constructed from fuel-resistant materials and configured to expand when filled with fuel and contract during fuel expulsion; a pressurized gas system configured to apply pressure to an exterior surface of the bladder to expel fuel from the bladder without mechanical pumps, the pressurized gas system including a gas reservoir and a gas distribution mechanism configured to provide controlled gas flow around the bladder; a fuel interface configured to provide access for introducing fuel into the bladder and for dispensing fuel from the bladder; and a pressurization interface configured to introduce pressurized gas into the gas reservoir.

[0015] In some cases, a pressurized fuel system with safety features may include: a tank containing a flexible bladder configured to store fuel; a gas reservoir positioned to provide pressurized gas for fuel expulsion; a pressure-activated mechanism configured to initiate fuel flow when a predetermined pressure threshold is exceeded, the pressure-activated mechanism including a burst disk that ruptures at a specific pressure level to allow fuel delivery; a fuel delivery interface configured to control fuel flow from the bladder; and a pressure control system configured to regulate gas pressure within the system, the pressure control system including at least one safety feature selected from the group consisting of a relief valve configured to prevent over-pressurization and a pressure sensor configured to monitor system pressure.

[0016] In some cases, a method of operating a pressurized fuel storage and delivery system may include: filling a flexible bladder positioned within a tank with liquid fuel; introducing pressurized gas into a gas reservoir positioned within the tank; maintainingthe pressurized gas in a ready state for fuel expulsion operations; and discharging fuel from the bladder by allowing the pressurized gas to flow from the gas reservoir to a space surrounding the bladder, causing the bladder to compress and expel the fuel through a fuel port.

[0017] In some cases, a method of thermal management in a pressurized fuel system may include: directing pressurized gas through microchannels formed on at least one surface selected from the group consisting of interior surfaces of a tank and an exterior surface of a bladder positioned within the tank; distributing cooling effects from gas expansion across extended surface areas using the microchannels to prevent localized temperature variations; controlling bladder compression patterns by guiding gas flow along predetermined pathways defined by the microchannels; and managing thermal effects during fuel expulsion operations by balancing cooling from gas expansion against heating from system components.

[0018] In some cases, a method of controlling a pressurized fuel storage and delivery system using a controller may include: receiving pressure data from at least one pressure sensor monitoring system pressure within a gas reservoir and a bladder chamber; determining fuel delivery parameters based on the received pressure data; monitoring fuel flow operations through sensor feedback; and adjusting system operation parameters to maintain predetermined pressure levels and fuel delivery rates based on the fuel delivery parameters and the fuel flow operations.

[0019] Additional objects and advantages of the disclosed technology will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of the disclosed technology.

[0020] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosed technology, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary aspects and together with the description, serve to explain the principles of the disclosed technology.

[0022] FIG. 1 illustrates a cross-sectional view of a fuel storage system with a pressurized bladder configuration, according to aspects of the present disclosure.

[0023] FIG. 2 illustrates a section view of a fuel storage system with a toroidal tank configuration, according to aspects of the present disclosure.

[0024] FIG. 3A illustrates a first system configuration of a pressurized fuel storage and delivery system, according to aspects of the present disclosure.

[0025] FIG. 3B illustrates a second system configuration of a pressurized fuel storage and delivery system, according to aspects of the present disclosure.

[0026] FIG. 3C illustrates a third system configuration of a pressurized fuel storage and delivery system, according to aspects of the present disclosure.

[0027] FIG. 3D illustrates a fourth system configuration with dual gas reservoirs of a pressurized fuel storage and delivery system, according to aspects of the present disclosure.

[0028] FIG. 4A illustrates a first gas distribution configuration with microchannels on tank interior surfaces, according to aspects of the present disclosure.

[0029] FIG. 4B illustrates a second gas distribution configuration with microchannels on bladder exterior surfaces, according to aspects of the present disclosure.

[0030] FIG. 4C illustrates a third gas distribution configuration with detailed microchannel features on interior wall surfaces, according to aspects of the present disclosure.

[0031] FIG. 5 illustrates a dual thread interface with sealing system for the tank, according to aspects of the present disclosure.

[0032] FIG. 6A illustrates a first safety configuration with a burst disk mechanism, according to aspects of the present disclosure.

[0033] FIG. 6B illustrates a second safety configuration with pressure sensors and controller integration, according to aspects of the present disclosure.

[0034] FIG. 6C illustrates a third safety configuration with auxiliary gas source and regulator components, according to aspects of the present disclosure.

[0035] FIG. 6D illustrates a fourth safety configuration with multiple relief valves and safety mechanisms, according to aspects of the present disclosure.

[0036] FIG. 7 illustrates a flowchart of a method for operating the pressurized fuel storage and delivery system, according to aspects of the present disclosure.

[0037] FIG. 8 illustrates a flowchart of a method for thermal management in the pressurized fuel system, according to aspects of the present disclosure.

[0038] FIG. 9 illustrates a flowchart of a method for controller-based operation of the pressurized fuel system, according to aspects of the present disclosure.

[0039] FIG. 10 depicts an example system that may execute techniques presented herein.DETAILED DESCRIPTION

[0040] The pressurized fuel storage and delivery system described herein may provide a pump-free approach to fuel storage and expulsion using pressurized gas to drive fuel delivery operations. The system may comprise a tank containing a flexible bladder that stores liquid fuel, with pressurized gas surrounding the bladder to compress and expel fuel when needed. This configuration may eliminate the need for mechanical pumps, reducing system complexity and potential failure points while providing reliable fuel delivery across various operating conditions.

[0041] The system may offer advantages in applications where traditional fuel delivery mechanisms face limitations. In some cases, the pressurized gas approach may enable fuel delivery regardless of orientation, acceleration, or gravitational conditions, making the system suitable for aerospace, automotive, and industrial applications. The absence of mechanical pumps may reduce maintenance requirements and improve operational reliability, particularly in harsh environments where pump mechanisms might be susceptible to failure.

[0042] Safety features may be incorporated into the system design to manage pressurization risks and ensure controlled fuel delivery. The system may include pressure relief mechanisms, monitoring sensors, and controlled pressurization interfaces to prevent over-pressurization and enable safe operation. In some cases, the system may incorporate burst disks or other pressure-activated mechanisms to initiate fuel flow under predetermined conditions.

[0043] The flexible bladder design may enable complete fuel utilization with minimal residual fuel remaining after expulsion operations. The bladder may collapse as fuel is expelled, ensuring that substantially all stored fuel can be delivered to the intended destination. This configuration may also eliminate fuel sloshing effects that can occur in rigid tank systems, providing more predictable fuel delivery characteristics.

[0044] Thermal management capabilities may be integrated into the system to address temperature variations that occur during pressurized gas expansion and fuel delivery operations. The system may incorporate features to distribute thermal effects across extended surface areas, preventing localized temperature extremes that could affect bladder integrity or fuel properties.

[0045] The toroidal bladder configuration may represent a fundamental advancement in fuel storage technology that addresses longstanding limitations of conventional bladder tank designs. Unlike spherical or cylindrical bladder tanks that require internal support structures to prevent complete collapse, the toroidal geometry may provide continuous circumferential support around the bladder's entire perimeter. This continuous support arrangement may eliminate the need for central posts, standpipes, or other internal structures that create flow obstructions and prevent complete fuel evacuation in traditional bladder systems.

[0046] The donut-shaped bladder geometry may enable the flexible membrane to collapse inward uniformly toward the central void, creating predictable fuel flow patterns that direct substantially all liquid fuel toward the exit port without creating stagnant zones or dead spaces. The toroidal configuration may distribute pressure forces around the circumference rather than concentrating loads at discrete support points, potentially reducing structural stress concentrations and enabling lighter-weight tank construction while maintaining pressure containment integrity.

[0047] The following detailed description may present various implementations and configurations of the pressurized fuel storage and delivery system, including different tank geometries, gas distribution mechanisms, safety features, and control systems. These implementations may demonstrate the versatility of the pressurized fuel delivery approach across different applications and operating requirements.1. Pressurized Fuel System

[0048] Referring to FIG. 1, a fuel storage system 100 may comprise several components arranged to provide pressurized fuel delivery without mechanical pumps. The fuel storage system 100 may include a tank 106 having interior surfaces that define a fuel storage volume. A flexible bladder 108 may be positioned within the tank 106 and configured to contain fuel. The bladder 108 may be constructed from fuel-resistant materials and configured to expand when filled with fuel and contract during fuel expulsion operations.

[0049] The tank 106 and the flexible bladder 108 may be different shapes from the generally cylindrical shape depicted in FIG. 1, such as spherical, toroidal, rectangular, elliptical, conical, or irregular geometries that conform to available installation spaces. In some aspects, the tank 106 may be configured with a toroidal shape to accommodate central pass-through requirements, while the bladder 108 may be shaped to optimize fuel storage volume within the available tank geometry. The bladder 108 may also be configured with complex three-dimensional shapes that maximize fuel capacity while maintaining structural integrity during pressurization cycles.

[0050] The toroidal tank configuration may provide significant space utilization advantages over conventional fuel storage approaches. In some cases, the donutshaped geometry may achieve up to 40% greater fuel storage volume within a given installation envelope compared to arrangements using multiple separate spherical tanks. This volume efficiency may result from the toroidal shape's ability to eliminate unusable corner spaces and dead volumes that occur when multiple discrete tanks are arranged within a confined space.

[0051] The central void space created by the toroidal geometry may enable revolutionary integration capabilities that are not achievable with conventional tank configurations. The hollow center may accommodate rotating shafts, drive mechanisms, structural members, electrical cables, hydraulic lines, or other system components while maintaining fuel storage capacity around the perimeter. This pass-through capability may enable new system architectures where fuel storage is integrated around existing equipment rather than competing for installation space, potentially reducing overall system footprint and complexity.

[0052] A gas reservoir 112 may be positioned within the tank 106 and configured to store pressurized gas. The gas reservoir 112 may be located in an upper portion of the tank 106, providing space for pressurized gas storage above the bladder 108. In some cases, the pressurized gas may comprise an inert gas such as nitrogen or compressed air, which may provide safe pressurization without risk of combustion or chemical reaction with stored fuel.

[0053] The gas reservoir 112 may be configured in various shapes and configurations to optimize space utilization and system performance within the tank 106. In some aspects, the gas reservoir 112 may be shaped as a cylindrical chamber, spherical volume, toroidal section, or irregular geometry that conforms to available space within the tank 106. The gas reservoir 112 may be positioned in different locations within the tank 106, such as at the top, bottom, or side portions, depending on system requirements and installation constraints.

[0054] In some cases, the gas reservoir 112 may be located remotely from the tank 106 and connected via a tube or port interface. This remote configuration may enable the gas reservoir 112 to be positioned in a separate location while maintaining pressurized gas delivery capability to the tank 106 through connecting conduits. The remote gas reservoir 112 may provide advantages in applications where space constraints within the tank 106 limit internal gas storage capacity, or where the gas reservoir 112 may benefit from being positioned in a different thermal or mechanical environment than the fuel storage components.

[0055] A micro-perforated separator 114 may be positioned between the gas reservoir 112 and the bladder 108. The micro-perforated separator 114 may be configured to allow controlled gas flow from the gas reservoir 112 to a space surrounding the bladder 108. This controlled gas flow arrangement may enable precise management of pressure application to the bladder 108, ensuring uniform compression and fuel expulsion when pressurized gas is released from the gas reservoir 112.

[0056] The micro-perforated separator 114 may comprise various physical arrangements designed to facilitate controlled gas distribution from the gas reservoir 112 to the bladder section. In some aspects, the micro-perforated separator 114 may include an array of holes that are strategically sized and positioned to regulate gas flowrates and distribution patterns. The holes may be arranged in uniform patterns across the separator surface, or may be configured with varying sizes and spacing to create specific flow characteristics that optimize bladder compression uniformity.

[0057] The micro-perforated separator 114 may be part of a gas distribution system that controls pressurized gas flow from the gas reservoir 112 to areas surrounding the bladder 108. The distribution system may alternatively comprise microchannels that direct gas flow along predetermined pathways from the gas reservoir 112 to areas surrounding the bladder 108. These microchannels may be formed as grooves, recessed pathways, or other surface features that guide pressurized gas distribution while maintaining separation between the gas reservoir 112 and bladder sections. The microchannels may be arranged in patterns such as radial, spiral, or branching configurations to ensure comprehensive gas distribution around the bladder 108.

[0058] In some cases, the distribution system may incorporate routing features that direct pressurized gas to multiple specific areas around the bladder 108. This routing arrangement may enable targeted pressure application to different bladder regions, allowing for controlled compression sequences that optimize fuel expulsion efficiency. The distribution system may include distribution manifolds, flow channels, or directional ports that ensure pressurized gas reaches predetermined locations around the bladder 108 perimeter.

[0059] The distribution system may also comprise combinations of the micro-perforated separator 11 , holes, microchannels, and routing features to provide enhanced gas distribution control. This multi-feature approach may enable both broad area gas distribution through hole arrays and targeted gas delivery through specific routing pathways, providing comprehensive pressure management capabilities that accommodate different bladder geometries and fuel expulsion requirements.

[0060] The fuel storage system 100 may include a pressurization port 102 connected to the gas reservoir 112. The pressurization port 102 may be configured to introduce pressurized gas into the gas reservoir 112 during system preparation operations. A removeable cap 104 may be connected to or sealed to the tank 106 to seal the gas reservoir 112 (see, e.g., FIG. 5). The pressurization port 102 may serve as apressurization interface that enables introduction of pressurized gas into the gas reservoir 112.

[0061] A fuel fill port 110 may provide access for introducing fuel into the bladder 108. The fuel fill port 110 may allow liquid fuel to be loaded into the bladder 108 during system preparation. A fuel exit port 120 may be configured to allow fuel delivery from the bladder 108 when the pressurized gas compresses the bladder 108. A valve 118 may be positioned near the fuel exit port 120 to control fuel flow during delivery operations. The fuel fill port 110 and fuel exit port 120 may together constitute a fuel interface that provides access for both introducing fuel into the bladder 108 and dispensing fuel from the bladder 108.

[0062] An internal fuel tube 116 may extend through the bladder 108 to provide consistent fuel flow during bladder collapse. The internal fuel tube 116 may improve operational reliability by maintaining a clear fuel flow path as the bladder 108 contracts during fuel expulsion. In some cases, the internal fuel tube 116 may incorporate a castellated end fitting to prevent premature sealing of the fuel exit port 120, providing enhanced flow reliability during fuel delivery operations. This configuration may prevent the bladder 108 from collapsing over the exit to the fuel exit port 120, ensuring continuous fuel delivery throughout the expulsion process.

[0063] The arrangement of components in the fuel storage system 100 may eliminate the need for complex mechanical pumps, reducing system complexity and maintenance requirements. The pressurized gas system may apply pressure to an exterior surface of the bladder 108 to expel fuel from the bladder 108 without mechanical pumps. The fuel bladder 108 may ensure fuel remains isolated from tank walls, reducing contamination, corrosion and likelihood of damage to the stored fuel. When pressurized gas flows from the gas reservoir 112 through the micro-perforated separator 114 to the space surrounding the bladder 108, the gas may compress the bladder 108 and force fuel through the fuel exit port 120, providing reliable fuel delivery without mechanical pumping mechanisms.

[0064] Referring to FIG. 2, a fuel storage system 200 may demonstrate a toroidal configuration that provides enhanced integration flexibility and space utilization. The fuel storage system 200 may include a tank 203 having an interior wall 205 and an exteriorwall 207 that define a toroidal fuel storage volume. This toroidal configuration may define a central void space that allows other components to pass through a center of the tank 203.

[0065] A central channel duct 220 may extend through the center of the tank 203, utilizing the central void space created by the toroidal configuration. The central channel duct 220 may be configured to accommodate components, power, communications, rotating shafts, etc. or carry compressed gases or heated fluids through the central void space while the fuel storage components occupy the surrounding toroidal volume. This arrangement may enable the fuel storage system 200 to be integrated around existing system components such as cables, drive shafts, or other equipment that requires central pass-through accommodation.

[0066] A bladder 206 may be positioned within the tank 203 and configured to occupy the toroidal volume around the central channel duct 220. The bladder 206 may conform to the toroidal shape defined by the interior wall 205 and exterior wall 207 of the tank 203. When filled with fuel, the bladder 206 may expand to utilize the available toroidal volume while maintaining clearance (e.g., by the interior wall) around the central channel duct 220.

[0067] A gas reservoir 204 may be positioned within the tank 203 and configured to store pressurized gas in the toroidal volume. The gas reservoir 204 may be located in an upper portion of the toroidal space, providing pressurized gas storage that surrounds the central channel duct 220. A micro-perforated separator 212 may be positioned between the gas reservoir 204 and the bladder 206 to provide controlled gas flow distribution around the toroidal volume.

[0068] The fuel storage system 200 may include a pressurization port 202 connected to the gas reservoir 204 for introducing pressurized gas. A removable cap 210 may seal the gas reservoir 204 to maintain pressurization after pressurization operations are complete. A fuel fill port 208 may provide access for introducing fuel into the bladder 206, while a fuel exit port 218 may enable fuel delivery from the bladder 206. A valve 216 may control fuel flow through the fuel exit port 218 during delivery operations.

[0069] An internal fuel tube 214 may extend within the bladder 206 to maintain fuel flow continuity as the bladder 206 contracts during fuel expulsion. The internal fuel tube 214may be configured to accommodate the toroidal geometry while providing consistent fuel delivery performance.

[0070] The toroidal configuration may provide space efficiency advantages by maximizing fuel storage volume within a given envelope while accommodating central pass-through requirements. This arrangement may enable the fuel storage system 200 to be fitted around cables, drive shafts, or other systems where the design requires central pass-through capability. The central void space may accommodate various system components without compromising the fuel storage capacity or pressurization functionality of the surrounding toroidal volume.

[0071] The elimination of internal support structures in the toroidal bladder design may provide substantial operational and manufacturing advantages over conventional bladder tank approaches. Traditional bladder tanks may require central posts, standpipes, or support masts to prevent the bladder from collapsing completely and blocking fuel flow pathways. These internal structures may create flow obstructions that prevent complete fuel evacuation, leaving unusable fuel residuals that reduce system efficiency. The internal supports may also create localized stress concentrations in the bladder material during pressurization cycles, potentially leading to premature failure or reduced service life.

[0072] The toroidal bladder configuration may avoid these limitations by providing natural structural support through the continuous circumferential housing contact, eliminating the need for internal obstructions. Without internal supports, the bladder may collapse completely during fuel expulsion operations, enabling virtually 100% fuel utilization with minimal residual fuel remaining in the system. The absence of internal structures may also simplify bladder manufacturing by eliminating the need to design membrane attachment points around support elements, potentially reducing production complexity and manufacturing costs.2. Configurations

[0073] Referring to FIG. 3A, a first system configuration 300A may demonstrate an alternative arrangement of fuel delivery components within a pressurized fuel storage system. The first system configuration 300A may include a tank 306 containing a bladder 308 for storing fuel. A gas reservoir 312 may be positioned above the bladder308, separated by a micro-perforated separator 314 that enables controlled gas flow distribution.

[0074] A pressurization port 302 may extend from the gas reservoir 312 to provide access for introducing pressurized gas into the system. A removable cap 304 may seal the gas reservoir 312 after pressurization operations are complete. The pressurization port 302 may provide a pressurization interface for system preparation.

[0075] A tube 316 may extend through the interior of the bladder 308 to maintain fuel flow continuity during expulsion operations. The tube 316 may prevent the bladder 308 from collapsing over fuel delivery pathways, ensuring consistent fuel flow as the bladder 308 contracts. In some cases, the tube 316 may incorporate a castellated end fitting to prevent premature sealing of an exit port, providing enhanced flow reliability during fuel delivery operations.

[0076] A valve 318 may be positioned at the bottom of the tank 306, connected to a fuel port 320A for controlling fuel flow from the bladder 308. The valve 318 may regulate fuel delivery operations by controlling when pressurized gas is allowed to compress the bladder 308 and expel fuel through the fuel port 320A.

[0077] The fuel port 320A may be configured as a dual-function interface that serves both fuel filling and fuel discharge operations, eliminating the need for separate fuel fill and fuel exit ports. This single-port configuration may reduce system complexity by minimizing the number of connections required while providing both fuel loading and delivery capabilities through a common interface. The fuel port 320A may incorporate directional flow control mechanisms that enable fuel to be introduced into the bladder 308 during filling operations and expelled from the bladder 308 during discharge operations.

[0078] In some aspects, the fuel port 320A may utilize pressure differentials to determine flow direction, allowing fuel to flow into the bladder 308 when external fuel pressure exceeds internal bladder pressure during filling operations, and enabling fuel to flow out of the bladder 308 when internal pressure from the pressurized gas exceeds external pressure during discharge operations. The valve 318 may provide flow control that coordinates with these pressure differentials to ensure proper operation during both filling and discharge phases.

[0079] The dual-function fuel port 320A may reduce potential sources of system failure by eliminating additional port connections that could develop leaks or require maintenance. Fewer connections may also reduce the likelihood of operator error during system preparation, as personnel need only connect to a single fuel interface rather than managing separate fill and discharge connections. This simplified interface may also reduce the risk of cross-contamination between fuel loading and delivery systems.

[0080] The fuel port 320A may incorporate check valve mechanisms or directional flow features that prevent backflow during operations while enabling bidirectional fuel transfer capabilities. In some cases, the fuel port 320A may include quick-disconnect fittings that facilitate rapid connection and disconnection of fuel supply lines during filling operations and fuel delivery lines during discharge operations. The single-port design may also enable the fuel port 320A to be positioned at an optimal location within the tank 306 for both filling efficiency and complete fuel evacuation during discharge.

[0081] The tube 316 extending through the bladder 308 may work in conjunction with the dual-function fuel port 320A to ensure that fuel can be effectively introduced during filling operations and completely evacuated during discharge operations. This arrangement may enable the fuel port 320A to provide access to fuel throughout the bladder 308 volume regardless of whether the bladder 308 is in an expanded state during filling or a contracted state during discharge.

[0082] Referring to FIG. 3B, a second system configuration 300B may illustrate an alternative fuel interface arrangement. The second system configuration 300B may include a tank 306 containing a bladder 308 with a gas reservoir 312 positioned above the bladder 308. A micro-perforated separator 314 may separate the gas reservoir 312 from the bladder 308 to provide controlled gas distribution.

[0083] The second system configuration 300B may incorporate a pressurization port 302 with a removable cap 304 for introducing pressurized gas into the gas reservoir 312. A bladder port interface 316B may connect to a valve 318 to control fuel flow operations. The second system configuration 300B may feature a fuel fill port 310 that allows fuel to be introduced into the bladder 308, while a fuel exit port 320 may enable fuel to be dispensed from the system.

[0084] In some cases, the fuel interface may comprise a single port configured to serve as both a fuel fill port and a fuel exit port. This configuration may simplify system design by reducing the number of required connections while providing both fuel loading and delivery capabilities through a common interface.

[0085] The bladder port interface 316B may provide a direct connection pathway between the bladder 308 and the valve 318 without requiring an internal tube structure. In some cases, the bladder 308 may discharge fuel smoothly enough during compression that the tube 316 may not be necessary for maintaining flow continuity. This direct interface approach may reduce potential sources of system failure by eliminating internal tube components that could become damaged, displaced, or create flow restrictions during bladder expansion and contraction cycles.

[0086] The bladder port interface 316B may reduce manufacturing complexity by eliminating the need to integrate internal tube components during bladder assembly operations. Without internal tube structures, the bladder 308 may be manufactured using simpler fabrication processes that reduce production costs and assembly time. The absence of internal components may also reduce the likelihood of manufacturing defects that could compromise bladder integrity or create internal flow obstructions.

[0087] In some aspects, the bladder port interface 316B may provide enhanced reliability by reducing the number of internal components that could potentially fail during operation. Internal tubes may be subject to mechanical stress during bladder compression cycles, potentially leading to tube displacement, cracking, or separation from connection points. The direct interface approach may eliminate these potential failure modes while maintaining effective fuel delivery performance.

[0088] The bladder port interface 316B may enable more uniform bladder compression patterns by allowing the bladder 308 to contract naturally without internal structural constraints. Internal tubes may create localized stress concentrations or prevent uniform bladder collapse, potentially leaving fuel residuals in areas around tube structures. The direct interface may allow the bladder 308 to compress more completely, potentially improving fuel evacuation efficiency.

[0089] The bladder port interface 316B may reduce potential for operator errors during system preparation or maintenance operations. Internal tube systems may requirespecific positioning or alignment procedures during bladder installation, creating opportunities for incorrect assembly that could compromise system performance. The direct interface approach may simplify installation procedures by eliminating internal tube positioning requirements.

[0090] In some cases, the bladder port interface 316B may provide improved fuel flow characteristics by eliminating flow restrictions that could occur at tube inlet or outlet points. Internal tubes may create pressure drops or flow turbulence that could affect fuel delivery rates or create uneven flow patterns. The direct interface may provide smoother flow transitions between the bladder interior and the valve 318, potentially improving overall fuel delivery performance.

[0091] Referring to FIG. 3C, a third system configuration 300C may demonstrate alternative port placement arrangements within the pressurized fuel storage system. The third system configuration 300C may include a tank 306 containing a bladder 308 for fuel storage. A gas reservoir 312 may be positioned within the tank 306, separated from the bladder 308 by a micro-perforated separator 314.

[0092] A pressurization port 302 with a removable cap 304 may allow pressurized gas to be introduced into the gas reservoir 312. A tube 316 may extend through the system to maintain fuel flow continuity. A valve 318C may control fuel flow through the system, while a fuel port 320C may provide an interface for fuel transfer into or out of the bladder 308. The third system configuration 300C may demonstrate that fuel ports may be positioned at various locations within the system while maintaining pressurized fuel delivery functionality.

[0093] The valve 318C and fuel port 320C may be positioned on different sides of the tank 306 based on specific system configuration requirements and installation constraints. This flexible positioning capability may enable the third system configuration 300C to accommodate various deployment scenarios where access points need to be oriented in different directions relative to the tank 306 geometry.

[0094] In some aspects, the valve 318C and the fuel port 320C may be positioned on one side of the tank 306 while the pressurization port 302 is located on an opposite side (see, e.g., FIG. 1), providing separated control and transfer interfaces that may facilitate different operational procedures. This separated positioning may enable the valve 318Cto be accessed for control operations from one direction while the fuel port 320C remains accessible for fuel transfer operations from another direction, accommodating installations where space constraints or equipment arrangements limit access to specific tank surfaces.

[0095] The flexible positioning of the valve 3180 and fuel port 320C may allow different configurations for deployment applications where the fuel storage system needs to be integrated into vehicles, aircraft, or industrial equipment with varying space constraints and access requirements. The valve 318C may be positioned to provide operator access for control functions, while the fuel port 320C may be oriented to align with fuel delivery systems or distribution networks that approach the tank 306 from different angles.

[0096] For filling station applications, the positioning flexibility may enable the fuel port 320C to be oriented toward fuel supply connections while the valve 318C is positioned for operator / system control during filling operations. This arrangement may facilitate efficient fuel loading (and discharge) procedures by allowing filling equipment (or discharge equipment, such as manifolds, injectors, etc.) to connect to the fuel port 320C while operators / systems maintain control access through the valve 318C from a separate location that provides better visibility or safety positioning during fuel transfer operations.

[0097] The different side positioning may also accommodate maintenance and service requirements where the valve 318C needs to be accessible for routine inspection or adjustment while the fuel port 320C may be positioned in areas that are less frequently accessed but provide optimal fuel flow characteristics. This configuration flexibility may enable system designers to optimize both operational convenience and performance characteristics based on specific application requirements and installation environments.

[0098] Referring to FIG. 3D, a fourth system configuration 300D may illustrate a dual reservoir arrangement that provides enhanced pressurization capabilities. The fourth system configuration 300D may include a tank 306 containing a bladder 308 and a tube 316 for maintaining fuel flow continuity.

[0099] The fourth system configuration 300D may feature a first gas reservoir 312D separated by a first micro-perforated separator 314D from the bladder 308, while a second gas reservoir 312DD may be separated by a second micro-perforated separator 314DD from the bladder 308. This dual reservoir configuration may provide enhanced gas distribution around the bladder 308, enabling more uniform pressure application during fuel expulsion operations.

[0100] The fourth system configuration 300D may feature a first pressurization port 302D and a second pressurization port 302DD for introducing pressurized gas into the system. A first cap 304D may seal the first gas reservoir 312D, while a second cap 304DD may seal the second gas reservoir 312DD after pressurization operations are complete.

[0101] A valve 318D may control flow through a fuel port 320D, providing regulated fuel delivery from the bladder 308. The dual reservoir arrangement may enable pressurized gas to be applied from multiple locations around the bladder 308, potentially improving fuel expulsion efficiency and providing redundancy in pressurization capabilities.

[0102] The dual reservoir configuration may be modified to utilize a single pressurization interface while maintaining the benefits of distributed gas storage. In some aspects, the second pressurization port 302DD may be omitted when the first gas reservoir 312D and second gas reservoir 312DD are connected through internal gas distribution pathways within the tank 306. This connected reservoir arrangement may enable pressurized gas to be introduced through the first pressurization port 302D and distributed to both the first gas reservoir 312D and second gas reservoir 312DD through connecting conduits or channels formed within the tank structure.

[0103] The connecting pathways between the first gas reservoir 312D and second gas reservoir 312DD may comprise internal gas distribution manifolds or microchannels / channels in / adjacent to the tank walls that ensure pressure equalization between the reservoirs while maintaining the distributed gas storage benefits. These manifolds may be formed as machined channels, cast passages, or separate tubing systems that enable gas flow between reservoir sections. The connecting pathways may incorporate flow control features such as orifices or restrictors that regulate gasdistribution rates between reservoirs, enabling controlled pressure buildup in different reservoir sections.

[0104] Alternative gas storage configurations may include multiple smaller gas reservoirs positioned around the bladder 308 perimeter to provide enhanced pressure distribution uniformity. These distributed reservoirs may be connected through a common gas distribution network that enables pressurization through a single pressurization port while providing gas storage at multiple locations around the bladder 308. The distributed reservoir approach may enable more precise control over bladder compression patterns by positioning gas storage volumes at strategic locations that optimize pressure application geometry.

[0105] In some cases, the gas storage configuration may comprise a continuous annular gas reservoir that surrounds the bladder 308, providing uniform gas distribution without requiring separate reservoir chambers. The annular reservoir may be formed as a toroidal volume within the tank 306 that encircles the bladder 308, enabling pressurized gas to be applied uniformly around the bladder circumference. This continuous reservoir approach may eliminate the need for multiple pressurization ports while providing comprehensive pressure coverage around the bladder 308.

[0106] The gas storage system may incorporate segmented reservoir configurations where the gas storage volume is divided into multiple sections that can be pressurized independently or collectively depending on operational requirements. The segmented approach may enable selective pressurization of different reservoir sections to create controlled compression sequences or to provide redundancy in case of reservoir section failure. Each segment may be connected to a common pressurization manifold that enables individual or collective pressurization through valve control systems.

[0107] Hierarchical gas storage arrangements may be implemented where a primary gas reservoir supplies pressurized gas to secondary distribution reservoirs positioned around the bladder 308. The primary reservoir may be connected to the pressurization port 302D and may supply gas to multiple secondary reservoirs through distribution valves or regulators that control gas flow to different bladder regions. This hierarchical approach may enable centralized gas storage with distributed pressure application capabilities.

[0108] The gas storage configuration may incorporate pressure staging systems where different reservoir sections operate at different pressure levels to create sequential compression effects. Higher pressure reservoirs may provide initial bladder compression while lower pressure reservoirs may provide sustained pressure during fuel expulsion operations. The pressure staging approach may optimize fuel delivery characteristics by matching pressure application to different phases of the fuel expulsion process.

[0109] The various system configurations shown in FIGS. 3A-3D may demonstrate the adaptability of the pressurized fuel storage and delivery system to different operational requirements and installation constraints. The system may be adapted to various sizes and configurations, making the system suitable for multiple industries including automotive and aerospace applications. Each configuration may maintain the fundamental pressurized gas approach to fuel delivery while accommodating different port arrangements, reservoir configurations, and integration requirements.3. Microchannel

[0110] Referring to FIG. 4A, a first gas distribution configuration 400A may demonstrate microchannel arrangements for controlling pressurized gas distribution and thermal management within a fuel storage system. The first gas distribution configuration 400A may include a tank 403 with an exterior wall 407A and an interior wall 405 that define a fuel storage volume. A bladder 406 may be positioned within the tank 403 to contain fuel during storage and delivery operations.

[0111] A gas reservoir 404 may be provided above the bladder 406 to store pressurized gas for fuel expulsion operations. A pressurization port 402 may be connected to the gas reservoir 404 to introduce pressurized gas into the system. A removable cap 410 may seal the gas reservoir 404 after pressurization operations are complete. A microperforated separator 412 may be positioned between the gas reservoir 404 and the bladder 406 to provide controlled gas distribution around the bladder 406.

[0112] The first gas distribution configuration 400A may incorporate an internal fuel tube 414 that extends through the bladder 406 to maintain fuel flow continuity during expulsion operations. A valve 416 may control flow through a fuel exit port 418, while a fuel fill port 408 may allow fuel to be introduced into the bladder 406. A central channelduct 420 may extend through the center of the configuration, providing space for other system components or fluid flow.

[0113] The exterior wall 407A may include a primary wall 420A with microfeatures 422A formed on interior surfaces of the tank 403. The microfeatures 422A may comprise microstructures 424A and microchannels 426A that are configured to distribute pressurized gas around the bladder 406. The microchannels 426A may be formed on the interior surfaces of the tank 403 to control bladder compression patterns and manage thermal effects during gas expansion.

[0114] The microchannels 426A may be configured to distribute cooling effects from gas expansion across extended surface areas to prevent localized temperature drops that could compromise bladder material properties. When pressurized gas expands from the gas reservoir 404 through the micro-perforated separator 412, the gas may undergo rapid cooling due to expansion effects. The microchannels 426A may distribute this cooling across the interior surfaces of the tank 403, preventing concentrated cold zones that could affect bladder 406 integrity or fuel properties.

[0115] The microchannels 426A may comprise a pattern selected from the group consisting of spiral patterns, axial patterns, longitudinal patterns, and branching patterns. In some cases, spiral patterns may create helical gas flow paths around a circumference of the bladder 406, providing uniform gas distribution as the pressurized gas flows from the gas reservoir 404. The microchannels 426A may comprise microstructures 424A selected from the group consisting of grooves, channels, recessed pathways, and dimples that are formed on the primary wall 420A.

[0116] Referring to FIG. 4B, a second gas distribution configuration 400B may illustrate microchannels formed on bladder surfaces rather than tank interior surfaces. The second gas distribution configuration 400B may include a tank 403 with an interior wall 405 and an exterior wall 407. A bladder 406B may be positioned within the tank 403 and configured to store fuel during system operations.

[0117] The second gas distribution configuration 400B may incorporate a central channel duct 420 extending through the system, along with a pressurization port 402 connected to a gas reservoir 404. A removable cap 410 may seal the gas reservoir 404, while a micro-perforated separator 412 may provide controlled gas flowdistribution. An internal fuel tube 414 may extend through the system, connecting to a valve 416 and a fuel exit port 418. A fuel fill port 408 may provide access for introducing fuel into the bladder 406B.

[0118] The bladder 406B may feature a primary bladder wall 420B with microfeatures 422B formed on an exterior surface of the bladder 406B. The microfeatures 422B may include microstructures 424B and microchannels 426B that are configured to manage gas flow and thermal effects. The microchannels 426B may be formed on the exterior surface of the bladder 406B to distribute pressurized gas around the bladder 406B and control compression patterns during fuel expulsion operations.

[0119] The microchannels 426B formed on the primary bladder wall 420B may provide direct thermal management at the bladder surface, distributing cooling effects from gas expansion across the exterior surface of the bladder 406B. This configuration may enable precise thermal control by managing temperature variations directly at the bladder material interface, potentially providing enhanced protection against thermal shock conditions that could compromise bladder material integrity.

[0120] Referring to FIG. 4C, a third gas distribution configuration 400C may demonstrate detailed microchannel arrangements and thermal management features. The third gas distribution configuration 400C may include a tank 403 with an exterior wall 407 and an interior wall 405C. A bladder 406B may be positioned within the tank 403 for fuel storage operations.

[0121] The third gas distribution configuration 400C may incorporate a pressurization port 402 connected to a gas reservoir 404, with a removable cap 410 sealing the gas reservoir 112. A micro-perforated separator 412 may provide controlled gas distribution between the gas reservoir 404 and the bladder 406B. An internal fuel tube 414 may connect to a valve 416 and fuel exit port 418, while a fuel fill port 408 may allow fuel introduction into the system. A central channel duct 420 may extend through the center of the configuration.

[0122] The interior wall 405C may include a primary wall 420C that features microfeatures 422C arranged to provide enhanced gas distribution and thermal management capabilities. The microfeatures 422C may include microstructures 424C and microchannels 426C formed on the surface of the primary wall 420C. Themicrostructures 424C and microchannels 426C may be arranged to distribute gas flow and manage thermal effects within the system during pressurized gas expansion and fuel delivery operations.

[0123] The microchannels 426C may have varying depths and widths configured to create varying compression zones where different bladder areas are compressed at different rates to optimize fuel expulsion efficiency. By controlling the dimensions and patterns of the microchannels 426C, the gas flow distribution may be tailored to provide specific compression sequences that ensure complete fuel expulsion while maintaining bladder integrity throughout the delivery process.

[0124] The microchannels 426C may be positioned to create cooling zones around the central channel duct 420 to counteract heating effects from compressed gases flowing through the central channel duct 420. In some cases, the central channel duct 420 may carry heated fluids or compressed gases that generate thermal energy. The microchannels 426C may provide thermal management by distributing cooling effects from gas expansion in areas surrounding the central channel duct 420, creating a thermal balance that maintains operating temperatures within acceptable ranges.

[0125] The microchannel configurations shown in FIGS. 4A-4C may demonstrate various approaches to managing pressurized gas distribution and thermal effects within fuel storage systems. The microchannels may be formed on interior surfaces of the tank, exterior surfaces of the bladder, or both surfaces to provide comprehensive thermal management and gas distribution control. These configurations may enable precise control over bladder compression patterns while managing thermal effects that occur during gas expansion and fuel delivery operations, providing enhanced system performance and reliability across various operating conditions.

[0126] The microfeatures 422A, 422B, and 422C may incorporate various structural elements that enhance gas distribution and thermal management capabilities within the pressurized fuel storage system. The microchannels 426A, 426B, and 426C may be defined by raised structural elements that guide gas flow along predetermined pathways while providing enhanced surface area for thermal management operations.

[0127] The microstructures 424A, 424B, and 424C may comprise ribs that form the solid lands between adjacent microchannels 426A, 426B, and 426C. The ribs may providestructural separation between gas flow pathways while maintaining the integrity of the microchannel patterns formed on the primary wall 420A, primary bladder wall 420B, or primary wall 420C. In some cases, the ribs may be configured with varying heights and widths to create different flow resistance characteristics that control gas distribution rates to different areas of the bladder 406 or bladder 406B.

[0128] The microstructures 424A, 424B, and 424C may alternatively comprise fins that extend into the gas flow pathways to enhance thermal management and mixing characteristics. The fins may be positioned between adjacent microchannels 426A, 426B, and 426C to increase surface area contact with the pressurized gas, enabling enhanced heat transfer during gas expansion operations. The fins may be configured with tapered profiles or pin-shaped geometries that optimize gas flow characteristics while maximizing thermal management effectiveness.

[0129] In some aspects, the microstructures 424A, 424B, and 424C may comprise discrete posts or pillars arranged in arrays across the surface of the primary wall 420A, primary bladder wall 420B, or primary wall 420C. The posts may be positioned to create micropost arrays or micropillar lattices that enhance gas mixing and provide controlled flow distribution around the bladder 406 or bladder 406B. The discrete post configuration may enable enhanced transport effects that improve gas distribution uniformity while providing structural support for the microchannel network.

[0130] The microstructures 424A, 424B, and 424C may comprise lands that represent the raised regions remaining after microfabrication processes create the microchannels 426A, 426B, and 426C. The lands may be formed through etching, machining, or molding processes that remove material to create the recessed microchannel pathways while leaving elevated structural elements that define the channel boundaries. The lands may provide structural integrity to the microchannel network while maintaining precise dimensional control over gas flow characteristics.

[0131] The microstructures 424A, 424B, and 424C may comprise ridges that extend along the length of the microchannels 426A, 426B, and 426C to provide directional gas flow guidance. The ridges may be configured with low-aspect-ratio profiles or wavelike geometries that create controlled flow patterns while minimizing pressure drop across the microchannel network. The ridge configuration may enable the microchannels 426A,426B, and 426C to maintain consistent gas flow direction while accommodating manufacturing tolerances and surface variations.

[0132] In some cases, the microstructures 424A, 424B, and 424C may comprise walls that form the boundaries of rectangular or trapezoidal microchannels 426A, 426B, and 426C. The walls may provide simple geometric boundaries that separate adjacent gas flow pathways while enabling straightforward manufacturing through machining, casting, or molding processes. The wall configuration may be suitable for applications where manufacturing simplicity and cost-effectiveness are priorities while maintaining adequate gas distribution and thermal management performance.

[0133] The microstructures 424A, 424B, and 424C may comprise bosses that provide localized flow partitioning or structural reinforcement within the microchannel network. The bosses may be positioned at strategic locations within the microchannels 426A, 426B, and 426C to create controlled flow separation or to provide mechanical support for thin-walled sections of the primary wall 420A, primary bladder wall 420B, or primary wall 420C. The boss configuration may enable enhanced structural integrity while maintaining controlled gas flow characteristics.

[0134] The selection of specific microstructure configurations may depend on manufacturing capabilities, performance requirements, and cost considerations for different applications. The microstructures 424A, 424B, and 424C may be formed through various manufacturing processes including precision machining, photolithography, etching, molding, or additive manufacturing techniques that enable creation of complex three-dimensional geometries with controlled dimensional accuracy.

[0135] The microchannels 426A, 426B, and 426C may incorporate combinations of different microstructure types to optimize both gas distribution and thermal management performance. In some aspects, the microchannel network may include ribs for structural support, fins for enhanced thermal management, and posts for improved gas mixing, creating a hybrid microstructure configuration that provides comprehensive performance optimization across multiple operational parameters.4. Dual Thread

[0136] Referring to FIG. 5, a dual thread interface 500 may provide a manufacturable sealing arrangement that enables cost-effective assembly of pressurized fuel storagecomponents. The dual thread interface 500 may be incorporated into a tank 502 to create pressure-tight connections while accommodating complex internal geometries and flow pathways.

[0137] The tank 502 may include an exterior thread 504 formed on an outer surface of the tank 502. The exterior thread 504 may provide a threaded connection interface for external components such as caps or connecting hardware. An interior thread 508 may be formed within the tank 502, providing a second threaded interface that enables dualthreaded assembly configurations. The combination of the exterior thread 504 and interior thread 508 may create a dual thread interface that allows complex sealing arrangements to be manufactured using standard lathe machining techniques.

[0138] A central channel duct 506 may extend through the center of the tank 502, providing a passage for compressed gases, heated fluids, or other system components. The central channel duct 506 may be accommodated within the dual thread interface 500 while maintaining pressure-tight sealing around the threaded connections. This arrangement may enable the tank 502 to provide both pressurized fuel storage capabilities and central pass-through functionality within a single integrated component.

[0139] The dual thread interface 500 may incorporate a sealing system that includes a first seal 510 and a second seal 512 positioned to create pressure-tight interfaces between threaded components. The first seal 510 may be positioned to seal around the exterior thread 504, while the second seal 512 may be positioned to seal around the interior thread 508. The first seal 510 and second seal 512 may work together to ensure that pressurized gas contained within the tank 502 does not leak through the threaded connections.

[0140] A gas reservoir 514 may be incorporated into the tank 502 structure, providing storage space for pressurized gas used in fuel expulsion operations. The gas reservoir 514 may be sealed from an exterior of the apparatus by the dual thread interface 500 arrangement. The sealing system may ensure that the gas reservoir 514 and the tank 502 are sealed from the exterior of the apparatus by a cap or by a component connected to the apparatus using the exterior thread 504 and the interior thread 508.

[0141] A micro perforated separator 516 may be positioned within the tank 502 to provide controlled gas distribution from the gas reservoir 514. The micro perforatedseparator 516 may allow pressurized gas to flow in a controlled manner while maintaining separation between different system chambers. A hole array 518 may extend through the tank 502 structure to provide gas flow pathways that connect the gas reservoir 514 to bladder sections of the tank 502.

[0142] The hole array 518 may be configured in various patterns and arrangements to provide tailored gas flow characteristics for different fuel delivery applications and operational requirements. The hole array 518 may comprise different hole arrangements that enable precise control over gas distribution rates, pressure application patterns, and thermal management effects during fuel expulsion operations.

[0143] The hole array 518 may be arranged in uniform patterns where holes are positioned at regular intervals across the micro perforated separator 516 surface. The uniform arrangement may provide consistent gas distribution characteristics that ensure even pressure application across the bladder surface during fuel expulsion. In some cases, the uniform pattern may comprise a grid arrangement where holes are positioned at intersections of perpendicular lines, creating predictable flow distribution that enables consistent fuel delivery performance across different operating conditions.

[0144] The hole array 518 may alternatively be configured in random patterns where hole positions are distributed irregularly across the separator surface. The random arrangement may provide enhanced gas mixing characteristics by creating turbulent flow patterns that improve pressure distribution uniformity. Random hole patterns may reduce the likelihood of flow channeling effects that could occur with regular patterns, ensuring that gas distribution reaches all areas of the bladder surface even when manufacturing tolerances or installation variations affect system geometry.

[0145] In some aspects, the hole array 518 may be arranged in concentric patterns where holes are positioned along circular or elliptical paths around a central axis of the tank 502. The concentric arrangement may be particularly suitable for cylindrical or toroidal tank configurations where radial gas distribution is desired. The concentric pattern may enable controlled pressure application that follows the natural geometry of circular bladders, providing efficient compression patterns that optimize fuel expulsion while maintaining bladder structural integrity.

[0146] The hole array 518 may comprise radial patterns where holes are arranged along lines extending outward from a central point or axis. The radial arrangement may provide directional gas flow that creates specific compression sequences during fuel expulsion operations. In some cases, the radial pattern may be combined with varying hole sizes to create pressure gradients that ensure fuel flows toward designated exit points while preventing stagnant zones that could trap residual fuel.

[0147] The hole array 518 may incorporate spiral patterns where holes are positioned along curved pathways that create helical gas flow characteristics. The spiral arrangement may provide enhanced gas mixing while creating rotational flow patterns that improve pressure distribution uniformity around the bladder perimeter. The spiral pattern may be particularly effective for applications where bladder geometry or fuel properties benefit from rotational compression effects during expulsion operations.

[0148] The hole array 518 may be configured with varying hole sizes within a single pattern to create different flow resistance characteristics across the separator surface. Larger holes may provide higher flow rates for rapid pressure application, while smaller holes may provide controlled flow rates for sustained pressure maintenance. The varying hole size approach may enable the hole array 518 to provide both initial rapid compression and sustained pressure application throughout the fuel expulsion process.

[0149] The hole array 518 may comprise clustered arrangements where groups of holes are positioned in specific regions to create localized high-flow zones. The clustered configuration may be suitable for applications where targeted pressure application is required to address specific bladder geometry constraints or fuel flow requirements. In some cases, clusters may be positioned near fuel exit points to ensure adequate pressure for complete fuel evacuation, while other areas may have lower hole density to prevent excessive pressure that could damage bladder materials.

[0150] The hole array 518 may incorporate graduated patterns where hole density varies across the separator surface to create controlled pressure gradients. Higher hole density regions may provide increased gas flow for areas requiring rapid compression, while lower density regions may provide gentler pressure application for areas containing sensitive bladder materials or complex geometries. The graduated approachmay enable optimization of both fuel expulsion efficiency and bladder longevity across different system configurations.

[0151] The hole array 518 may be designed with directional characteristics where holes are angled or shaped to create preferred gas flow directions. Angled holes may direct gas flow toward specific bladder regions or away from sensitive components, while shaped holes may create flow patterns that enhance mixing or reduce pressure drop across the separator. The directional approach may enable precise control over gas distribution patterns that accommodate specific application requirements or installation constraints.

[0152] The hole array 518 may comprise multi-stage configurations where different hole sizes or patterns are arranged in layers or sections to provide sequential gas flow characteristics. The multi-stage approach may enable initial rapid pressure application through large holes, with sustained pressure maintenance through smaller holes, creating optimized fuel expulsion profiles that adapt to changing system conditions during delivery operations.

[0153] The dual thread interface 500 may enable the tank 502 to be manufactured using standard lathe machining operations rather than more expensive welding techniques such as electron beam welding. The threading arrangement may allow complex internal geometries to be created through machining operations, with the dual threaded connections providing secure sealing without requiring welded joints. This manufacturing approach may reduce production costs while maintaining the structural integrity and pressure-tight sealing required for pressurized fuel storage applications.

[0154] The exterior thread 504 and interior thread 508 may be machined simultaneously during lathe operations, ensuring precise alignment and fit between the threaded interfaces. The first seal 510 and second seal 512 may be positioned in machined grooves or recesses that are created during the same lathe operations, providing integrated sealing surfaces that align with the threaded connections. This integrated manufacturing approach may eliminate the need for separate welding operations while providing reliable pressure-tight sealing around the central channel duct 506 and gas reservoir 514 interfaces.

[0155] The toroidal bladder design may enable significant manufacturing advantages through simplified component construction and assembly processes. The continuous donut-shaped bladder may be manufactured as a single integral membrane without requiring complex internal fittings, support attachments, or multi-piece assembly operations that are typically necessary in conventional bladder tank designs. This simplified bladder construction may reduce manufacturing steps, minimize potential leak points, and improve overall system reliability by eliminating internal connection interfaces that could fail during operation.

[0156] The manufacturing approach may enable cost-effective production through the use of standard machining operations rather than specialized welding or forming processes. The toroidal tank housing may be produced using conventional lathe operations, milling equipment, or other standard manufacturing tools, potentially reducing production costs compared to systems requiring electron beam welding, specialized forming dies, or complex assembly fixtures. The modular design approach may also enable parallel manufacturing of bladder, housing, and gas distribution components, allowing independent quality control testing of each element before final system assembly.5. Safety and Control

[0157] Referring to FIG. 6A, a first safety configuration 600A may demonstrate safety mechanisms for controlling fuel flow initiation in pressurized fuel systems. The first safety configuration 600A may include a tank 606 containing a bladder 608 configured to store fuel during system operations. A gas reservoir 612 may be positioned to provide pressurized gas for fuel expulsion operations. A pressurization port 602 may be connected to a removable cap 604 to enable introduction of pressurized gas into the gas reservoir 612.

[0158] A micro perforated separator 614 may be positioned between the gas reservoir 612 and the bladder 608 to provide controlled gas distribution around the bladder 608. A bladder port interface 616 may extend through the tank 606 to provide a connection pathway for fuel delivery operations. The bladder port interface 616 may be connected to a valve 618 that controls flow through a fuel port 620.

[0159] The first safety configuration 600A may incorporate a coupling 622A connected to the pressurization port 602 to provide an interface for pressure-activated mechanisms. The coupling 622A may be configured to provide an interface for a burst disk and a valve to control pressurized gas flow delivery operations. A burst disk 626A may be incorporated into the configuration as part of a pressure-activated mechanism configured to blow and off gas to prevent damage to the system during set up.

[0160] The burst disk 626A may be designed to rupture at a predetermined pressure threshold that is set below the maximum safe operating pressure of the system components. During system setup operations, if pressurization levels exceed the safe threshold due to operator error, equipment malfunction, or excessive gas supply pressure, the burst disk 626A may rupture to release excess gas and prevent overpressurization damage to the tank 606, bladder 608, or other system components.

[0161] The burst disk 626A may be calibrated to activate at a specific pressure level that provides adequate safety margin while allowing normal operational pressures to be achieved during proper system setup procedures. In some cases, the burst disk 626A may be configured to rupture at pressures that are 10-20% above normal operating pressure but well below the pressure levels that could cause structural damage to system components. This calibration may enable the burst disk 626A to provide protection against accidental over-pressurization while not interfering with normal gas delivery operations.

[0162] The burst disk 626A may be constructed from materials that provide predictable rupture characteristics under pressure conditions. The disk material may be selected to ensure clean rupture patterns that create adequate venting area when activated, enabling rapid pressure relief that prevents pressure buildup beyond safe limits. In some aspects, the burst disk 626A may comprise scored or weakened sections that control the rupture pattern and ensure consistent activation behavior across different environmental conditions.

[0163] The coupling 622A may provide a mounting interface that enables the burst disk 626A to be positioned in the gas flow path where it can monitor system pressure and activate when threshold conditions are exceeded. The coupling 622A may incorporate threaded connections or other attachment mechanisms that allow the burst disk 626A tobe securely mounted while providing access for replacement after activation. The coupling 622A may also include flow passages that direct vented gas away from personnel and equipment when the burst disk 626A ruptures.

[0164] The burst disk 626A may serve as a one-time safety device that requires replacement after activation to restore system protection capabilities. The coupling 622A may be designed to facilitate field replacement of the burst disk 626A, enabling system reset and reuse after over-pressurization events. In some cases, the coupling 622A may incorporate visual indicators or other features that clearly show when the burst disk 626A has been activated, alerting operators to the need for disk replacement before subsequent system operations.

[0165] The pressure-activated mechanism may provide automatic protection that does not require electrical power or control systems to function. The burst disk 626A may operate purely through mechanical pressure response, making it suitable for applications where electrical safety systems may not be available or reliable. This mechanical activation approach may provide fail-safe protection that continues to function even when other system components experience failures or power interruptions.

[0166] Pressurized gas 624 may be introduced to the system to enable fuel expulsion operations. When the pressurized gas 624 creates sufficient pressure conditions, the burst disk 626A may rupture to ensure system / user safety. The burst disk 626A may be replaceable and configured to be removed and replaced after activation to enable system reset for subsequent operations. The coupling 622A may provide a replaceable interface for the burst disk 626A and may incorporate threading to allow field replacement of the burst disk 626A after activation.

[0167] Referring to FIG. 6B, a second safety configuration 600B may illustrate monitoring and control capabilities for pressurized fuel systems. The second safety configuration 600B may include a tank 606 containing a bladder 608 and a gas reservoir 612. A micro perforated separator 614 may be positioned between the gas reservoir 612 and the bladder 608 to provide controlled gas distribution. A bladder port interface 616 may extend through the tank 606, while a pressurization port 602 with a removable cap 604 may provide access for introducing pressurized gas 624 into the system.

[0168] The second safety configuration 600B may incorporate a monitoring and control system including pressure sensors and control components. A first sensor 623 may be configured to monitor system pressure within the gas reservoir 612. A second sensor 621 may provide additional pressure monitoring from within the bladder 608. The first sensor 623 and second sensor 621 may be configured to monitor system pressure and provide pressure data for system control operations.

[0169] A controller 625 may be connected to the first sensor 623 and second sensor 621 and configured to receive pressure data and control system operations based on monitored pressure levels. The controller 625 may be configured to receive pressure data from the pressure sensors monitoring system pressure within the gas reservoir 612 and bladder 608. The controller 625 may determine gas delivery parameters based on the received pressure data and may adjust system operation parameters to maintain predetermined pressure levels and fuel delivery rates.

[0170] A coupling valve 622B may be positioned along the pressurized gas 624 flow path to provide controlled gas flow management, based on control signals from the controller 625. The coupling valve 622B may work in conjunction with the controller 625 to regulate pressurized gas flow based on sensor feedback from the first sensor 623 and second sensor 621. A valve 618 may control flow through a fuel port 620, with the valve 618 potentially being controlled by the controller 625 based on pressure monitoring data.

[0171] The controller 625 may be configured to maintain pressure levels in the gas reservoir 612 throughout fuel delivery operations by controlling introduction of additional pressurized gas (see, e.g., FIG. 6C). The monitoring and control system may enable precise management of fuel delivery operations while providing safety oversight through continuous pressure monitoring and automated control responses.

[0172] Referring to FIG. 6C, a third safety configuration 600C may demonstrate pressure maintenance and regulation capabilities during fuel delivery operations. The third safety configuration 600C may include a tank 606 containing a bladder 608 and a gas reservoir 612. A micro perforated separator 614 may be positioned between the gas reservoir 612 and the bladder 608. A pressurization port 602 with a removable cap 604 may provide access for introducing pressurized gas into the gas reservoir 612.

[0173] A bladder port interface 616 may connect to a coupling manifold valve 622C that provides flow control and distribution capabilities. The coupling manifold valve 622C may be configured to provide an interface for pressure-activated mechanisms and flow regulation components. A burst disk 626C may be positioned along the fuel flow path to provide pressure-activated fuel flow initiation. The burst disk 626C may rupture at a specific pressure level to allow fuel delivery when predetermined pressure conditions are achieved.

[0174] A regulator 629 may be positioned along a fuel flow path to maintain consistent fuel output pressure and flow rate. The regulator 629 may be configured to maintain consistent fuel output pressure and flow rate regardless of variations in gas reservoir pressure or bladder volume changes during fuel expulsion. The regulator 629 may be positioned along the fuel flow path between the bladder 608 and a fuel exit port to provide controlled fuel delivery characteristics throughout the expulsion process.

[0175] The third safety configuration 600C may incorporate an auxiliary gas source 631 connected to the system through an auxiliary gas valve 632. The auxiliary gas source 631 and auxiliary gas valve 632 may enable introduction of additional pressurized gas during fuel delivery operations to maintain consistent pressure levels in the gas reservoir 612 (or to maintain the pressure during staging / storage). The controller 625 may be connected to system components to monitor and control operations, including management of the auxiliary gas valve 632 to control introduction of additional pressurized gas from the auxiliary gas source 631 and the coupling manifold valve 622C.

[0176] Fuel 627 may flow through the system under control of the regulator 629 and coupling manifold valve 622C. The system may be configured to operate in blow-down mode where gas pressure in the gas reservoir 612 gradually decreases as fuel is expelled from the bladder 608, with initial gas pressure set to provide adequate fuel delivery pressure throughout an entire fuel expulsion process. Alternatively, the auxiliary gas source 631 may provide pressure maintenance to sustain consistent delivery pressure throughout fuel expulsion operations.

[0177] With continued reference to FIG. 60, the third safety configuration 600C may demonstrate how multiple safety and control components may work together to providereliable fuel delivery with pressure regulation capabilities. The combination of the burst disk 626C, regulator 629, auxiliary gas source 631 , and controller 625 may enable precise fuel delivery control while maintaining safety through pressure monitoring and regulation mechanisms.

[0178] The controller 625 may provide comprehensive system management through integration of sensor data and automated control algorithms that enable dynamic response to changing operational conditions / instructions. The controller 625 may receive real-time pressure data from the first sensor 623 and second sensor 621 , along with additional sensor inputs that may include temperature sensors, flow rate sensors, and position sensors positioned throughout the system ("sensor data"). This multisensor data integration may enable the controller 625 to develop a comprehensive understanding of system state and performance characteristics during fuel storage, pressurization, and delivery operations, and take action based on that information.

[0179] The controller 625 may process sensor data through control algorithms that analyze pressure trends, flow characteristics, and thermal conditions to generate system-level commands for various control components. The control algorithms may incorporate predictive modeling that anticipates system behavior based on current sensor readings and historical performance data. In some cases, the controller 625 may utilize feedback control loops that continuously compare actual system performance to predetermined target parameters, generating corrective commands when deviations are detected.

[0180] Dynamic relief valve control may be implemented through the controller 625 managing electronically-actuated relief valves that can be opened or closed based on real-time pressure monitoring. The controller 625 may receive pressure data from multiple sensors positioned throughout the system and may command relief valve operation when pressure levels approach predetermined safety thresholds. In some aspects, the controller 625 may provide graduated relief valve control where different relief valves are activated at different pressure levels, enabling staged pressure relief that prevents sudden pressure drops while maintaining system safety.

[0181] The controller 625 may manage manifold operations through control of the coupling manifold valve 622C and additional manifold components that direct fuel flowto multiple delivery points. The controller 625 may receive flow rate data from sensors positioned within manifold pathways and may adjust manifold valve positions to balance flow distribution among multiple outlets. Dynamic manifold control may enable the controller 625 to redirect fuel flow based on demand signals from different system components or to compensate for blockages or restrictions in specific delivery pathways.

[0182] Fuel rate control may be achieved through the controller 625 managing the regulator 629 and other flow control components based on sensor feedback regarding actual fuel delivery rates. The controller 625 may receive flow rate data from sensors positioned along fuel delivery pathways and may adjust regulator settings to maintain target flow rates despite variations in system pressure or bladder volume. In some cases, the controller 625 may provide variable fuel rate control where delivery rates are adjusted based on operational requirements or system conditions detected through sensor monitoring.

[0183] The controller 625 may coordinate auxiliary gas source 631 operations through control of the auxiliary gas valve 632 based on pressure monitoring data from the gas reservoir 612. When sensor data indicates that gas reservoir pressure is declining during fuel expulsion operations, the controller 625 may command the auxiliary gas valve 632 to introduce additional pressurized gas to maintain targeted pressure levels. The controller 625 may calculate the timing and duration of auxiliary gas introduction based on fuel expulsion rates and remaining bladder volume to optimize pressure maintenance throughout the delivery process.

[0184] Temperature-based control may be implemented through the controller 625 receiving thermal data from sensors positioned near the bladder 608, gas reservoir 612, and other system components. The controller 625 may adjust gas flow rates or timing based on temperature conditions to prevent thermal shock or excessive heating that could affect system performance. In some aspects, the controller 625 may coordinate thermal management by controlling gas distribution patterns through microchannels or other thermal management features based on temperature sensor feedback.

[0185] The controller 625 may provide system-level coordination by managing multiple control components simultaneously to optimize overall system performance. Thecontroller 625 may coordinate relief valve operation with manifold control and fuel rate adjustment to ensure that safety measures do not interfere with fuel delivery requirements. Dynamic system coordination may enable the controller 625 to balance competing operational requirements such as maintaining safety margins while achieving target fuel delivery rates under varying operational conditions.

[0186] Adaptive control capabilities may be incorporated into the controller 625 through machine learning algorithms or adaptive control systems that modify control parameters based on system performance history. The controller 625 may analyze sensor data patterns over multiple operational cycles to identify optimal control strategies for different operating conditions. In some cases, the controller 625 may adjust control algorithms based on environmental conditions, fuel properties, or system aging effects detected through long-term sensor data analysis.

[0187] Emergency response protocols may be implemented through the controller 625 providing rapid system shutdown or emergency venting capabilities when sensor data indicates potentially dangerous conditions. The controller 625 may monitor multiple sensor inputs simultaneously and may activate emergency relief valves, close fuel delivery valves, or initiate other protective measures when sensor data indicates overpressurization, thermal excursions, or other hazardous conditions. The emergency response capabilities may provide automated protection that responds faster than manual operator intervention while maintaining system safety under fault conditions.

[0188] Referring to FIG. 6D, a fourth safety configuration 600D may illustrate comprehensive over-pressurization protection for fuel storage and delivery systems. The fourth safety configuration 600D may include a tank 606 containing a bladder 608 for fuel storage operations. A pressurization port 602 with a removable cap 604 may be positioned at an upper portion of the tank 606 to provide access for introducing pressurized gas into the system.

[0189] A gas reservoir 612 may be separated from the bladder 608 by a micro perforated separator 614 to provide controlled gas distribution. A bladder port interface 616 may provide connection pathways for fuel delivery operations. The fourth safety configuration 600D may include a fuel fill port 610 that provides access for introducing fuel into the bladder 608 during system preparation operations.

[0190] The fourth safety configuration 600D may incorporate a safety system including multiple relief valves positioned to prevent over-pressurization during different operational phases. A relief valve 628 may be connected to the fuel fill port 610 (e.g., after filling) to provide over-pressurization protection or a means to discharge the fuel safely after / during fuel loading operations. A relief valve 630 may be positioned near the pressurization port 602 to provide over-pressurization protection during gas loading and system operation phases.

[0191] The relief valve 628 and relief valve 630 may together comprise multiple relief valves including a first relief valve connected to the pressurization port 602 and a second relief valve positioned near a fuel port. The relief valves may be configured to prevent over-pressurization of the tank 606 by venting excess pressure when predetermined pressure thresholds are exceeded during filling or operational phases.

[0192] A burst disk 626D may be positioned between the bladder port interface 616 and the fuel flow path to provide pressure-activated flow control. The burst disk 626D may provide a pressure-activated mechanism that initiates fuel flow when predetermined pressure conditions are achieved, while the relief valve 628 and relief valve 630 may provide over-pressurization protection to prevent pressure levels from exceeding safe operational limits.

[0193] The fourth safety configuration 600D may demonstrate how multiple safety mechanisms may be integrated to provide comprehensive protection against overpressurization while maintaining fuel delivery capabilities. The combination of the relief valve 628, relief valve 630, and burst disk 626D may provide safety features that protect against over-pressurization during filling operations, operational phases, and fuel delivery initiation, ensuring safe system operation across all operational modes, while also ensuring fuel delivery at / during, e.g., launch.

[0194] The safety configurations shown in FIGS. 6A-6D may demonstrate various approaches to managing pressure control and safety in pressurized fuel storage and delivery systems. These configurations may incorporate burst disks for pressure-activated fuel flow initiation, pressure sensors and controllers for monitoring and automated control, regulators for maintaining consistent fuel delivery characteristics, and relief valves for over-pressurization protection. The safety systems may providecomprehensive protection while enabling reliable fuel delivery operations across various operating conditions and applications.6. Flowcharts

[0195] Referring to FIG. 7, a method 700 for operating a pressurized fuel storage and delivery system may provide systematic procedures for fuel loading, pressurization, and controlled fuel delivery operations. The method 700 may enable reliable fuel expulsion without mechanical pumps while incorporating safety measures and operational flexibility across various applications.

[0196] The method 700 may begin with an operation 702 that involves filling a flexible bladder positioned within a tank with liquid fuel. The operation 702 may comprise introducing fuel through the fuel fill port 110 while venting displaced air through an expansion port (e.g., the pressurization port 102). During the operation 702, fuel may be loaded into the bladder 108 while air initially present in the bladder 108 is displaced and vented to prevent air entrapment that could interfere with fuel delivery operations. An expansion port may include a one-way valve to prevent air re-entry during operation, ensuring that the bladder 108 maintains proper fuel containment after filling operations are complete.

[0197] The method 700 may proceed to an operation 704 where pressurized gas is introduced into the gas reservoir 112 positioned within the tank 106. The operation 704 may involve connecting a pressurized gas source (e.g., storage tank or motorized pump) to the pressurization port 102 and introducing pressurized gas into the gas reservoir 112. The operation 704 may comprise providing the burst disk 626A or the relief valve 630 connected to the pressurization port 602 to prevent over-pressurization during gas filling operations by venting excess gas when pressure exceeds a predetermined safety threshold.

[0198] The pressurized gas introduced during the operation 704 may comprise an inert gas selected from the group consisting of nitrogen and compressed air. In some cases, the pressurizing gas may be other inert compressible gases beyond nitrogen or compressed air, depending on application requirements and compatibility with stored fuel types. The operation 704 may incorporate safety mechanisms to ensure that gas pressure levels remain within safe operational limits during pressurization procedures.

[0199] The method 700 may continue with an operation 706 which involves maintaining the pressurized gas in a ready state for fuel expulsion operations. The operation 706 may comprise monitoring pressure levels in the gas reservoir 612 using the first sensor 623 or other pressure sensors positioned within the system. During the operation 706, the pressurized gas 624 may be maintained at predetermined pressure levels that provide adequate driving force for fuel expulsion when delivery operations are initiated.

[0200] The operation 706 may involve sealing the pressurization port 602 with the removable cap 604 after pressurization operations are complete, maintaining system pressure until fuel delivery is required. The operation 706 may enable the system to remain in a ready state for extended periods, providing operational flexibility for applications where fuel delivery timing may be variable or unpredictable.

[0201] The method 700 may conclude with an operation 708 where fuel is discharged from the bladder 608 by allowing the pressurized gas 624 to flow from the gas reservoir 612 to a space surrounding the bladder 608, causing the bladder 608 to compress and expel the fuel 627 through the fuel port 620. The operation 708 may comprise activating the burst disk626C positioned along a fuel flow path when launch conditions create pressure levels exceeding a predetermined threshold. The burst disk 626C may provide mechanical activation of fuel flow without requiring electrical control systems, enabling fuel delivery initiation based on pressure conditions rather than electronic signals.

[0202] The operation 708 may involve distributing the discharged fuel through a manifold system connected to the fuel port 620 to deliver fuel to multiple destinations. The coupling manifold valve 622C may provide flow distribution capabilities that enable fuel delivery to multiple system components or delivery points from a single pressurized fuel storage system. This manifold distribution capability may enhance system versatility by enabling centralized fuel storage with distributed delivery capabilities.

[0203] During the operation 708, the method 700 may comprise adding additional pressurized gas to the gas reservoir 612 during fuel discharge operations to maintain consistent pressure levels throughout fuel expulsion. The auxiliary gas source 631 and auxiliary gas valve 632 may provide supplemental pressurized gas during fuel delivery operations, preventing pressure decay that could reduce fuel delivery performance as the bladder 608 contracts and available gas volume increases.

[0204] The operation 708 may comprise regulating fuel flow rate during discharge operations using the regulator 629 positioned along a fuel flow path. The regulator 629 may maintain consistent fuel output pressure and flow rate regardless of variations in gas reservoir pressure or bladder volume changes during fuel expulsion, providing controlled fuel delivery characteristics throughout the expulsion process.

[0205] The method 700 may comprise preventing over-pressurization during any of the filling, introducing, maintaining, or discharging steps using the relief valve 628 or other relief valves positioned within the system. The relief valve 628 and relief valve 630 may provide safety protection throughout all operational phases, ensuring that pressure levels do not exceed safe limits during fuel loading, gas pressurization, pressure maintenance, or fuel delivery operations.

[0206] The valve 618 may be either manually operated or automated depending on the application, providing operational flexibility for different system requirements. In some cases, automated valve control may be provided through the controller 625, while manual valve operation may be suitable for applications where direct operator control is preferred or where electronic control systems are not available.

[0207] The method 700 may enable the system to operate in harsh conditions where excessive G-forces or other factors would limit traditional fuel systems from operating. The pressurized gas approach may provide reliable fuel delivery regardless of orientation, acceleration, or gravitational conditions, making the method 700 suitable for aerospace, automotive, and industrial applications where conventional fuel delivery mechanisms might experience performance limitations due to environmental conditions.

[0208] Referring to FIG. 8, a method 800 for thermal management in a pressurized fuel system may provide systematic procedures for controlling temperature variations and managing thermal effects during pressurized gas expansion and fuel delivery operations. The method 800 may enable precise thermal control while maintaining efficient fuel expulsion performance across various operating conditions and system configurations.

[0209] The method 800 may begin with an operation 802 that involves directing pressurized gas through the microchannels 426A formed on at least one surface selected from the group consisting of interior surfaces of the tank 403 and an exteriorsurface of the bladder 406 positioned within the tank 403. The operation 802 may comprise creating gas flow patterns selected from the group consisting of spiral patterns, axial patterns, longitudinal patterns, and branching patterns. The spiral patterns may create helical gas flow paths around a circumference of the bladder 406, while axial patterns may direct gas flow along longitudinal axes of the tank 403.Longitudinal patterns may provide gas distribution along the length of the bladder 406, while branching patterns may create distributed flow networks that reach multiple areas of the bladder 406 surface simultaneously.

[0210] During the operation 802, the pressurized gas 624 may flow from the gas reservoir 404 through the micro-perforated separator 412 and into the microchannels 426A, 426B, or 426C formed on the interior surfaces of the tank 403 or the exterior surface of the bladder 406B. The microchannels 426A may comprise the microstructures 424A selected from the group consisting of grooves, channels, recessed pathways, and dimples that guide gas flow along predetermined pathways. The operation 802 may enable controlled gas distribution that prevents concentrated pressure application while ensuring comprehensive coverage of bladder surfaces during thermal management operations.

[0211] The operation 802 may enable an operation 804 where cooling effects from gas expansion are distributed across extended surface areas using the microchannels 426A, 426B, 426C to prevent localized temperature variations. The operation 804 may comprise preventing thermal shock conditions that could compromise bladder material integrity by distributing rapid cooling effects that occur when pressurized gas expands from the gas reservoir 404. When pressurized gas undergoes expansion, the gas may experience significant temperature reduction due to thermodynamic expansion effects. The microchannels 426A, 426B, 426C may distribute these cooling effects across the extended surface areas of the tank 403 interior surfaces or the bladder 406 exterior surface, preventing concentrated cold zones that could affect material properties or fuel characteristics.

[0212] The microchannels 426A, 426B, 426C may enable thermal energy distribution across the primary wall 420A or the primary bladder wall 420B, ensuring that cooling effects are spread over larger surface areas rather than concentrated at specific gasinlet points. The operation 804 may comprise maintaining fuel and bladder temperatures within predetermined operating ranges by distributing thermal effects across the microchannels 426A. This thermal distribution capability may prevent localized temperature drops that could cause bladder material to become brittle or could affect fuel flow characteristics during delivery operations.

[0213] The operation 802 may enable an operation 806 which involves controlling bladder compression patterns by guiding gas flow along predetermined pathways defined by the microchannels 426A, 426B, 426C. The operation 806 may comprise creating varying compression zones using the microchannels 426A, 426B, 426C having varying depths and widths to compress different bladder areas at different rates. The microchannels 426A, 426B, 426C may be configured with different cross-sectional dimensions and flow resistance characteristics that control the timing and sequence of gas flow to different bladder regions.

[0214] The microchannels 426A, 426B, 426C may enable precise control over how the bladder 406 compresses during fuel expulsion operations. The microchannels 426A with varying depths may provide different flow rates to different bladder areas, creating varying compressions that optimize fuel expulsion efficiency. Areas of the bladder 406 connected to deeper microchannels 426A, 426B, 426C may receive pressurized gas more rapidly, while areas connected to shallower microchannels 426A, 426B, 426C may experience delayed / different compression, creating controlled compression patterns that ensure complete fuel evacuation while maintaining bladder integrity.

[0215] The operation 806 may comprise optimizing fuel expulsion efficiency by ensuring uniform / varied pressure application across bladder surfaces through controlled gas distribution via the microchannels 426A, 426B, 426C. The predetermined pathways defined by the microchannels 426A, 426B, 426C may guide gas flow to ensure that all areas of the bladder 406 receive adequate pressure for fuel expulsion while preventing excessive pressure concentrations that could damage the bladder 406 or create uneven fuel flow characteristics.

[0216] The operation 802 may enable an operation 808 where thermal effects during fuel expulsion operations are managed by balancing cooling from gas expansion against heating from system components. The operation 808 may comprisecounteracting heating effects from the central channel duct 420 extending through a center of the tank 403 by positioning the microchannels 426C to create cooling zones around the central channel duct 420. In some cases, the tank 403 may comprise a toroidal configuration defining a central void space, and the central channel duct 420 may carry compressed gases or heated fluids through the central void space.

[0217] During the operation 808, the microchannels 426C may be positioned to provide cooling effects in areas where the central channel duct 420 generates thermal energy that could affect the bladder 406 or stored fuel. The central channel duct 420 may carry compressed gases that generate heat due to compression effects, or may carry heated fluids that transfer thermal energy to surrounding components. The microchannels 426C may distribute cooling effects from gas expansion in strategic locations around the central channel duct 420, creating thermal balance that maintains operating temperatures within acceptable ranges.

[0218] The operation 808 may enable thermal management that prevents excessive heating of the bladder 406 or fuel while simultaneously managing cooling effects from gas expansion. The microchannels 426C may provide thermal control that balances these competing thermal effects, ensuring that neither excessive heating nor excessive cooling compromises system performance or component integrity during fuel expulsion operations.

[0219] In some cases, the microchannels 426C may be formed on both the interior surfaces of the tank 403 (e.g., the interior wall and / or the exterior wall 207) and the exterior surface of the bladder 406B to provide enhanced thermal management capabilities. This dual-surface microchannel arrangement may enable comprehensive thermal control by managing temperature effects at both the tank interface and the bladder interface, providing enhanced thermal management performance for applications with demanding thermal control requirements.

[0220] The method 800 may enable thermal management across various system configurations, including systems with the central channel duct 420 that carries heated fluids or compressed gases, and systems without central heating sources where thermal management focuses primarily on managing cooling effects from gas expansion. The microchannels 426A, 426B, 426C may be configured with differentpatterns, depths, and widths to accommodate specific thermal management requirements for different applications and operating conditions.

[0221] Referring to FIG. 9, a method 900 for controlling a pressurized fuel storage and delivery system using the controller 625 may provide systematic procedures for automated system management, pressure monitoring, and coordinated fuel delivery operations. The method 900 may enable precise control over fuel expulsion operations while incorporating safety monitoring, thermal management coordination, and operational readiness verification across various system configurations and applications.

[0222] The method 900 may begin with an operation 902 that involves receiving pressure data from at least one pressure sensor monitoring system pressure within the gas reservoir 612 or a bladder. The operation 902 may comprise receiving pressure data from the first sensor 623 and the second sensor 621 positioned within different system chambers to provide comprehensive pressure monitoring capabilities. The first sensor 623 may monitor pressure levels within the gas reservoir 612, while the second sensor 621 may monitor pressure conditions within the bladder or other system locations.

[0223] During the operation 902, the controller 625 may receive real-time pressure data from multiple sensors positioned within different system chambers, enabling comprehensive monitoring of pressure conditions throughout the pressurized fuel storage and delivery system. The pressure sensors may provide continuous data regarding pressure levels, pressure variations, and pressure trends that occur during system preparation, pressure maintenance, and fuel delivery operations. The operation 902 may enable the controller 625 to maintain awareness of system pressure conditions across multiple locations simultaneously, providing data for coordinated system control decisions.

[0224] The method 900 may proceed to an operation 904 where fuel delivery parameters are determined based on the received pressure data. The operation 904 may involve analyzing pressure readings from the first sensor 623 and the second sensor 621 to calculate appropriate fuel delivery parameters such as delivery timing, flow rates, and pressure requirements. The controller 625 may determine fuel deliveryparameters by comparing received pressure data to predetermined operational thresholds and system requirements.

[0225] During the operation 904, the controller 625 may provide operational readiness verification by analyzing pressure readings from multiple sensors positioned within different system chambers. The operation 904 may involve determining whether pressure levels in the gas reservoir 612 are adequate for fuel delivery operations, whether bladder chamber pressure conditions are appropriate for fuel expulsion, and whether system pressure conditions meet safety requirements for operational initiation. The fuel delivery parameters determined during the operation 904 may include target fuel output pressure, desired flow rates, delivery duration, and safety margin requirements based on the received pressure data.

[0226] The method 900 may continue with an operation 906 which involves monitoring fuel flow operations through sensor feedback. The operation 906 may comprise receiving real-time data regarding fuel delivery rates and system pressure variations during fuel expulsion operations. The controller 625 may monitor fuel flow operations by receiving continuous feedback from the first sensor 623 and the second sensor 621 during fuel delivery operations, enabling real-time assessment of fuel expulsion performance and system response characteristics.

[0227] During the operation 906, the controller 625 may monitor changes in pressure levels within the gas reservoir 612 as pressurized gas flows to compress the bladder 608, and may monitor pressure variations within the bladder chamber as fuel is expelled through the fuel port 620. The operation 906 may enable the controller 625 to track fuel delivery progress, identify potential flow restrictions or performance variations, and assess whether fuel delivery operations are proceeding according to predetermined parameters established during the operation 904.

[0228] The method 900 may conclude with an operation 908 where system operation parameters are adjusted to maintain predetermined pressure levels and fuel delivery rates based on the fuel delivery parameters and the fuel flow operations. The operation 908 may comprise controlling valves, manifolds, etc. and maintaining constant pressure levels in the gas reservoir 612 throughout fuel delivery operations by controllingintroduction of additional pressurized gas from the auxiliary gas source 631 through the auxiliary gas valve 632.

[0229] During the operation 908, the controller 625 may adjust system operation parameters by controlling the regulator 629 positioned along a fuel flow path to match a target fuel output pressure and flow rate regardless of variations in gas reservoir pressure. The controller 625 may control the regulator 629 to maintain consistent fuel delivery characteristics as pressure conditions change during fuel expulsion operations, ensuring that fuel delivery rates remain within predetermined parameters throughout the expulsion process.

[0230] The operation 908 may comprise managing the coupling manifold valve 622C to control fuel flow distribution to multiple delivery points based on system requirements. The controller 625 may coordinate fuel distribution through the coupling manifold valve 622C to direct fuel to specific delivery locations or to control fuel flow rates to different system components based on operational requirements and fuel delivery parameters determined during the operation 904.

[0231] The method 900 may comprise implementing safety protocols by monitoring for over-pressurization conditions and activating relief mechanisms when pressure thresholds are exceeded. The controller 625 may monitor pressure data received during the operation 902 to identify over-pressurization conditions and may activate the relief valve 628 or the relief valve 630 when pressure levels exceed safe operational limits. The safety protocols may provide automated protection against over-pressurization during fuel loading, pressure maintenance, or fuel delivery operations.

[0232] The system may comprise coordinating thermal management operations by controlling gas distribution patterns to balance cooling effects from gas expansion against heating effects from system components. The system may coordinate thermal management by controlling gas flow through the microchannels 426A, 426B, or 426C to manage thermal effects during pressurized gas expansion and fuel delivery operations. The system may use the gas distribution patterns to maintain operating temperatures within acceptable ranges while ensuring efficient fuel expulsion performance.

[0233] The system may coordinate thermal management operations by managing gas / fuel flow timing and distribution to prevent excessive cooling from gas expansionwhile counteracting heating effects from the central channel duct 420 or other system components that generate thermal energy during operation. The thermal management coordination may involve controlling the timing and sequence of gas / fuel flow to balance thermal effects while maintaining fuel delivery performance.

[0234] The method 900 may enable automated system control that reduces operator workload while providing enhanced safety monitoring and performance optimization. The controller 625 may provide continuous system oversight through the operations 902, 904, 906, and 908, enabling responsive system control that adapts to changing conditions during fuel storage, pressure maintenance, and fuel delivery operations. The method 900 may be suitable for applications where automated control provides advantages over manual operation, such as aerospace systems, remote installations, or applications where rapid response to changing conditions enhances system performance and safety.

[0235] The pressurized fuel storage and delivery system may achieve reliable fuel storage and delivery across different operating conditions through coordinated integration of tank construction, bladder design, gas distribution mechanisms, and safety features. The system components may work together to provide pump-free fuel delivery while maintaining operational reliability under extreme conditions including high acceleration environments, variable orientations, and temperature variations.

[0236] The tank construction may utilize various materials and configurations to accommodate different application requirements and installation constraints. In some cases, the tank may be constructed from flexible mesh materials such as kevlar weave, allowing the fuel apparatus to conform to irregular shapes. The flexible mesh construction may enable the tank to be fitted into non-standard spaces or around existing equipment while maintaining structural integrity under pressurization. The kevlar weave or similar flexible mesh materials may provide tensile strength to contain pressurized gas while allowing the overall tank shape to adapt to available installation space.

[0237] The flexible mesh tank construction may maintain pressure containment capabilities while providing shape adaptability that rigid tank constructions cannot achieve. The mesh materials may be selected for compatibility with stored fuel typesand pressurized gas, ensuring that the flexible construction does not compromise chemical resistance or pressure containment performance. The flexible mesh approach may enable the fuel storage system to be integrated into applications where space constraints or irregular geometries would prevent installation of conventional rigid tanks.

[0238] Alternative tank configurations may include bifurcated designs that provide enhanced gas distribution and storage capabilities. The tank may be bifurcated into two sections, one for the fuel bladder and the second separated through small ports to serve as an air reservoir. The bifurcated configuration may separate the fuel storage volume from the gas reservoir volume through controlled connection pathways that enable gas flow while maintaining distinct chambers for different system functions.

[0239] The bifurcated tank design may provide improved gas distribution by positioning the air reservoir section in locations that optimize pressure application to the fuel bladder section. The small ports connecting the bifurcated sections may control gas flow rates and distribution patterns, enabling precise management of pressure application during fuel expulsion operations. The bifurcated approach may enable the air reservoir section to be positioned in areas of the tank that do not interfere with fuel storage volume while providing effective pressure distribution to the fuel bladder section.

[0240] The separation between bifurcated sections may be achieved through internal barriers or partitions that divide the tank volume while maintaining controlled communication through the small ports. The small ports may be sized and positioned to provide appropriate gas flow characteristics while maintaining separation between the fuel storage and gas storage functions. This bifurcated arrangement may enable optimization of both fuel storage capacity and gas distribution effectiveness within a single integrated tank structure.

[0241] The fuel bladder construction may incorporate various materials and reinforcement approaches to ensure reliable performance under pressurization and fuel expulsion cycles. The fuel bladder may be made of reinforced elastomers or specialized polymers that provide chemical compatibility with stored fuels while maintaining flexibility and durability under repeated pressurization cycles. The reinforced elastomers may be selected for resistance to fuel degradation, temperature variations, and mechanical stress that occurs during bladder expansion and contraction operations.

[0242] The fuel bladder may incorporate reinforcement layers or internal ribbing systems to prevent folding or collapsing during fuel expulsion operations. The reinforcement layers may be integrated into the bladder wall structure to provide additional strength in areas subject to high stress during pressurization. The internal ribbing system may provide structural support that maintains bladder shape and prevents irregular folding that could interfere with fuel flow or create stress concentrations that could lead to bladder failure.

[0243] The reinforcement approaches may include fiber reinforcement embedded within the elastomer matrix, providing enhanced tensile strength while maintaining flexibility. The specialized polymers may be selected for specific fuel compatibility requirements, with different polymer formulations available for different fuel types including hydrocarbon fuels, alcohol-based fuels, or other liquid propellants. The reinforcement layers may be positioned at predetermined locations within the bladder structure to provide support where stress analysis indicates enhanced strength requirements.

[0244] The internal ribbing system may comprise raised features or structural elements formed into the bladder interior surface that provide shape stability while allowing fuel flow around the ribbing features. The ribbing system may be designed to prevent complete bladder collapse while ensuring that fuel can flow freely to the bladder outlet during expulsion operations. The ribbing patterns may be optimized to provide structural support without creating flow restrictions or areas where fuel could become trapped during expulsion.

[0245] The system may be scaled and adapted for various applications while maintaining core functional advantages of pump-free operation and reliable performance in extreme conditions. The scalability may be achieved through proportional sizing of tank volumes, bladder capacities, gas reservoir volumes, and pressurization requirements to match specific application fuel delivery needs. Small-scale implementations may provide fuel storage for portable equipment or small vehicles, while large-scale implementations may provide fuel storage for industrial equipment or large vehicles.

[0246] The adaptation capabilities may include modification of tank geometries to accommodate different installation requirements, adjustment of pressurization levels tomatch different fuel delivery pressure requirements, and selection of materials to provide compatibility with different fuel types and operating environments. The core pump-free operation advantage may be maintained across all scale variations, providing reliable fuel delivery without mechanical pumps regardless of system size or application requirements.

[0247] The extreme condition performance capabilities may be maintained through appropriate selection of materials, pressurization levels, and safety features that accommodate the specific environmental conditions expected in different applications. High-acceleration applications may utilize enhanced bladder reinforcement and higher pressurization levels to ensure fuel delivery under extreme G-force conditions.Temperature-extreme applications may incorporate thermal management features and material selections that maintain performance across wide temperature ranges.

[0248] The system integration approach may enable the various components to work together synergistically, with tank construction providing structural support and shape adaptability, bladder design providing fuel containment and expulsion capability, gas distribution mechanisms providing controlled pressure application, and safety features providing operational protection. The integrated system may provide reliable fuel storage and delivery performance that exceeds the capabilities of individual components operating independently, demonstrating the advantages of the coordinated system approach across diverse applications and operating conditions.

[0249] The synergistic integration of toroidal geometry, microchannel gas distribution, and elimination of internal supports may create a comprehensive fuel storage solution that addresses multiple limitations of conventional approaches simultaneously. The toroidal bladder configuration may provide space efficiency advantages while enabling complete fuel evacuation, the microchannel system may ensure uniform pressure application while managing thermal effects, and the absence of internal structures may simplify manufacturing while improving operational reliability. This integrated approach may represent a fundamental advancement in fuel storage technology that enables new applications and system architectures not achievable with traditional fuel tank designs.

[0250] The toroidal fuel storage system may enable applications where conventional tank geometries would be impractical or impossible to implement. The central pass-through capability may allow fuel storage to be integrated around drive shafts in rotating machinery, around structural members in space vehicles, or around central equipment in compact installations where space constraints prevent the use of separate fuel tanks. The predictable collapse characteristics and complete fuel evacuation capability may make the system particularly suitable for mission-critical applications where fuel starvation or incomplete fuel utilization could compromise operational success.7. Computer System

[0251] FIG. 10 depicts an example system that may execute techniques presented herein. FIG. 10 is a simplified functional block diagram of a computer that may be configured to execute techniques described herein, according to exemplary cases of the present disclosure. Specifically, the computer (or “platform” as it may not be a single physical computer infrastructure) may include a data communication interface 1060 for packet data communication. The platform may also include a central processing unit (“CPU”) 1020, in the form of one or more processors, for executing program instructions. The platform may include an internal communication bus 1010, and the platform may also include a program storage and / or a data storage for various data files to be processed and / or communicated by the platform such as ROM 1030 and RAM 1040, although the system 1000 may receive programming and data via network communications. The system 1000 also may include input and output ports 1050 to connect with input and output devices such as keyboards, mice, touchscreens, monitors, displays, etc. Of course, the various system functions may be implemented in a distributed fashion on a number of similar platforms, to distribute the processing load. Alternatively, the systems may be implemented by appropriate programming of one computer hardware platform.

[0252] The general discussion of this disclosure provides a brief, general description of a suitable computing environment in which the present disclosure may be implemented. In some cases, any of the disclosed systems, methods, and / or graphical user interfaces may be executed by or implemented by a computing system consistent with or similar to that depicted and / or explained in this disclosure. Although not required, aspects of the present disclosure are described in the context of computer-executable instructions, such as routines executed by a data processing device, e.g., a server computer,wireless device, and / or personal computer. Those skilled in the relevant art will appreciate that aspects of the present disclosure can be practiced with other communications, data processing, or computer system configurations, including:Internet appliances, hand-held devices (including personal digital assistants (“PDAs”)), wearable computers, all manner of cellular or mobile phones (including Voice over IP (“VoIP”) phones), dumb terminals, media players, gaming devices, virtual reality devices, multi-processor systems, microprocessor-based or programmable consumer electronics, set-top boxes, network PCs, mini-computers, mainframe computers, and the like. Indeed, the terms “computer,” “server,” and the like, are generally used interchangeably herein, and refer to any of the above devices and systems, as well as any data processor.

[0253] Aspects of the present disclosure may be embodied in a special purpose computer and / or data processor that is specifically programmed, configured, and / or constructed to perform one or more of the computer-executable instructions explained in detail herein. While aspects of the present disclosure, such as certain functions, are described as being performed exclusively on a single device, the present disclosure may also be practiced in distributed environments where functions or modules are shared among disparate processing devices, which are linked through a communications network, such as a Local Area Network (“LAN”), Wide Area Network (“WAN”), and / or the Internet. Similarly, techniques presented herein as involving multiple devices may be implemented in a single device. In a distributed computing environment, program modules may be located in both local and / or remote memory storage devices.

[0254] Aspects of the present disclosure may be stored and / or distributed on non-transitory computer-readable media, including magnetically or optically readable computer discs, hard-wired or preprogrammed chips (e.g., EEPROM semiconductor chips), nanotechnology memory, biological memory, or other data storage media. Alternatively, computer implemented instructions, data structures, screen displays, and other data under aspects of the present disclosure may be distributed over the Internet and / or over other networks (including wireless networks), on a propagated signal on a propagation medium (e g., an electromagnetic wave(s), a sound wave, etc.) over aperiod of time, and / or they may be provided on any analog or digital network (packet switched, circuit switched, or other scheme).

[0255] Program aspects of the technology may be thought of as “products” or “articles of manufacture” typically in the form of executable code and / or associated data that is carried on or embodied in a type of machine-readable medium. “Storage” type media include any or all of the tangible memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide non-transitory storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the software from one computer or processor into another, for example, from a management server or host computer of the mobile communication network into the computer platform of a server and / or from a server to the mobile device. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links, or the like, also may be considered as media bearing the software. As used herein, unless restricted to non-transitory, tangible “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.8. Terminology

[0256] The terminology used above may be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific examples of the present disclosure. Indeed, certain terms may even be emphasized above; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this Detailed Description section. Both the foregoing general description and the detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed.

[0257] As used herein, the terms “comprises,” “comprising,” “having,” including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process,method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus.

[0258] In this disclosure, relative terms, such as, for example, “about,” “substantially,” “generally,” and “approximately” are used to indicate a possible variation of ±10% in a stated value.

[0259] As used herein, the terms "transmit," "provide," “receive,” and “obtain” may refer to the transfer or communication of data, information, or signals between various components or entities. This may include, but is not limited to, transmission over a network (such as a local area network, wide area network, or the Internet), transfer between devices (such as between computers, smartphones, or other electronic devices), communication between central processing units (CPUs) or graphics processing units (GPUs), exchange of information between microservices, transfer of data between software components within an environment, or any other form of data transfer or communication as indicated by the context in which the terms are used. The specific mode or medium of transmission or provision may vary depending on the particular implementation and system architecture.

[0260] As used herein, the term "module" may refer to software code, a software component, a software function, a software application, and firmware. As indicated by context, "module" may be logical, digital, analog, optical, electronic, or quantum implementations of operations or functions. A module may be implemented as a standalone unit or as part of a larger system. In some cases, a module may interact with other modules or components to perform specific tasks or operations within the system. As indicated by context or based on design preference, any two modules may be combined. As indicated by context or based on design preference, any module may be broken into two or more modules that provide some or all of the operations or functions of the single module. The specific implementation of module(s) may vary depending on the requirements of the system and the particular application.

[0261] The term “exemplary” is used in the sense of “example” rather than “ideal.” As used herein, the singular forms “a,” “an,” and “the” include plural reference unless the context dictates otherwise.9. Examples

[0262] Exemplary embediments ef the systems and metheds disclesed herein are described in the numbered paragraphs belcw.

[0263] A1. A pressurized fuel stcrage and delivery system, comprising: a tank having interior surfaces defining a fuel storage volume; a flexible bladder positioned within the tank and configured to contain fuel; a gas reservoir positioned within the tank and configured to store pressurized gas; a micro-perforated separator positioned between the gas reservoir and the bladder, the micro-perforated separator configured to allow controlled gas flow from the gas reservoir to a space surrounding the bladder; microchannels formed on at least one surface selected from the group consisting of the interior surfaces of the tank and an exterior surface of the bladder, the microchannels configured to distribute the pressurized gas around the bladder to control bladder compression patterns and manage thermal effects during gas expansion; a pressurization port connected to the gas reservoir and configured to introduce pressurized gas into the gas reservoir; and a fuel port connected to the bladder and configured to allow fuel delivery from the bladder when the pressurized gas compresses the bladder.

[0264] A2. The pressurized fuel storage and delivery system of A1 , wherein the microchannels are configured to distribute cooling effects from gas expansion across extended surface areas to prevent localized temperature drops that could compromise bladder material properties.

[0265] A3. The pressurized fuel storage and delivery system of A2, wherein the tank further comprises a central channel duct extending through a center of the tank, and the microchannels are positioned to create cooling zones around the central channel duct to counteract heating effects from compressed gases flowing through the central channel duct.

[0266] A4. The pressurized fuel storage and delivery system of any of A1-A3, wherein the microchannels comprise a pattern selected from the group consisting of spiral patterns, axial patterns, longitudinal patterns, and branching patterns.

[0267] A5. The pressurized fuel storage and delivery system of A4, wherein the spiral patterns create helical gas flow paths around a circumference of the bladder.

[0268] A6. The pressurized fuel storage and delivery system of any of A1-A5, wherein the microchannels are formed on the interior surfaces of the tank.

[0269] A7. The pressurized fuel storage and delivery system of any of A1-A6, wherein the microchannels are formed on the exterior surface of the bladder.

[0270] A8. The pressurized fuel storage and delivery system of any of A1-A7, wherein the microchannels comprise microstructures selected from the group consisting of grooves, channels, recessed pathways, and dimples.

[0271] A9. The pressurized fuel storage and delivery system of any of A1-A8, wherein the microchannels have varying depths and widths configured to create varying compression zones where different bladder areas are compressed at different rates to optimize fuel expulsion efficiency.

[0272] A10. The pressurized fuel storage and delivery system of any of A1-A9, wherein the pressurized gas comprises an inert gas selected from the group consisting of nitrogen and compressed air.

[0273] B1. A fuel storage and delivery apparatus, comprising: a rigid tank configured to contain pressurized components; a flexible bladder positioned within the tank and configured to store liquid fuel, the bladder being constructed from fuel-resistant materials and configured to expand when filled with fuel and contract during fuel expulsion; a pressurized gas system configured to apply pressure to an exterior surface of the bladder to expel fuel from the bladder without mechanical pumps, the pressurized gas system including a gas reservoir and a gas distribution mechanism configured to provide controlled gas flow around the bladder; a fuel interface configured to provide access for introducing fuel into the bladder and for dispensing fuel from the bladder; and a pressurization interface configured to introduce pressurized gas into the gas reservoir.

[0274] B2. The fuel storage and delivery apparatus of B1 , wherein the tank comprises a toroidal configuration defining a central void space that allows other components to pass through a center of the tank.

[0275] B3. The fuel storage and delivery apparatus of B2, wherein the central void space accommodates a central channel duct configured to carry compressed gases or heated fluids.

[0276] B4. The fuel storage and delivery apparatus of B2, wherein the tank comprises a dual thread interface including an exterior thread and an interior thread, and a sealing system including a first seal and a second seal positioned to create pressure-tight interfaces between threaded components, so that the gas reservoir and the tank are sealed from an exterior of the apparatus by a cap or by a component connected to the apparatus using force threads to the exterior thread and the interior thread.

[0277] B5. The fuel storage and delivery apparatus of any of B1-B4, wherein the gas distribution mechanism comprises at least one of a micro-perforated separator or microchannels, wherein the micro-perforated separator is positioned between the gas reservoir and the bladder, and the microchannels are formed on at least one surface selected from the group consisting of interior surfaces of the tank and an exterior surface of the bladder.

[0278] B6. The fuel storage and delivery apparatus of any of B1-B5, further comprising a coupling selected from the group consisting of a coupling manifold and a coupling valve, the coupling configured to provide an interface for at least one of a burst disk and a valve to control pressurized gas flow or fuel delivery operations.

[0279] B7. The fuel storage and delivery apparatus of any of B1-B6, further comprising a monitoring and control system including at least one of a pressure sensor, a controller, or a regulator, wherein the at least one pressure sensor is configured to monitor system pressure, the controller is connected to the at least one pressure sensor and configured to receive pressure data and control system operations, and the regulator is positioned along a fuel flow path and configured to maintain consistent fuel output pressure and flow rate.

[0280] B8. The fuel storage and delivery apparatus of any of B1-B7, wherein the fuel interface comprises a single port configured to serve as both a fuel fill port and a fuel exit port.

[0281] B9. The fuel storage and delivery apparatus of any of B1-B8, further comprising a safety system including at least one of relief valve or a burst disk configured to prevent over-pressurization of the tank.

[0282] B10. The fuel storage and delivery apparatus of any of B1-B9, further comprising a safety system including at least one of a burst disk or a controllable valve configured to initiate fuel flow.

[0283] C1. A pressurized fuel system with safety features, comprising: a tank containing a flexible bladder configured to store fuel; a gas reservoir positioned to provide pressurized gas for fuel expulsion; a pressure-activated mechanism configured to initiate fuel flow when a predetermined pressure threshold is exceeded, the pressure-activated mechanism including a burst disk that ruptures at a specific pressure level to allow fuel delivery; a fuel delivery interface configured to control fuel flow from the bladder; and a pressure control system configured to regulate gas pressure within the system, the pressure control system including at least one safety feature selected from the group consisting of a relief valve configured to prevent over-pressurization and a pressure sensor configured to monitor system pressure.

[0284] C2. The pressurized fuel system of C1, wherein the burst disk is replaceable and configured to be removed and replaced after activation to enable system reset for subsequent operations.

[0285] C3. The pressurized fuel system of C2, wherein the pressure-activated mechanism further comprises a coupling that provides a replaceable interface for the burst disk and incorporates threading to allow field replacement of the burst disk.

[0286] C4. The pressurized fuel system of any of C1-C3, wherein the pressure control system further comprises a controller connected to the pressure sensor and configured to receive pressure data and control fuel delivery operations based on monitored pressure levels.

[0287] C5. The pressurized fuel system of C4, wherein the controller is configured to maintain pressure levels in the gas reservoir throughout fuel delivery operations by controlling introduction of additional pressurized gas.

[0288] 06. The pressurized fuel system of any of C1-C5, wherein the fuel delivery interface comprises a regulator configured to maintain consistent fuel output pressure and flow rate regardless of variations in gas reservoir pressure or bladder volume changes during fuel expulsion.

[0289] C7. The pressurized fuel system of C6, wherein the regulator is positioned along a fuel flow path between the bladder and a fuel exit port.

[0290] C8. The pressurized fuel system of any of C1-C7, wherein the pressure control system comprises multiple relief valves including a first relief valve connected to a pressurization port and a second relief valve positioned near a fuel port.

[0291] C9. The pressurized fuel system of any of C1-C8, further comprising a microperforated separator positioned between the gas reservoir and the bladder and configured to provide controlled gas distribution around the bladder.

[0292] C10. The pressurized fuel system of C9, wherein the system is configured to operate in blow-down mode where gas pressure in the gas reservoir gradually decreases as fuel is expelled from the bladder, with initial gas pressure set to provide adequate fuel delivery pressure throughout an entire fuel expulsion process.

[0293] D1. A method of operating a pressurized fuel storage and delivery system, comprising: filling a flexible bladder positioned within a tank with liquid fuel; introducing pressurized gas into a gas reservoir positioned within the tank; maintaining the pressurized gas in a ready state for fuel expulsion operations; and discharging fuel from the bladder by allowing the pressurized gas to flow from the gas reservoir to a space surrounding the bladder, causing the bladder to compress and expel the fuel through a fuel port.

[0294] D2. The method of D1 , wherein introducing pressurized gas comprises providing a burst disk or relief valve connected to the pressurization port to prevent overpressurization during gas filling operations by venting excess gas when pressure exceeds a predetermined safety threshold.

[0295] D3. The method of any of D1-D2, wherein discharging fuel comprises activating a burst disk positioned along a fuel flow path when launch conditions create pressure levels exceeding a predetermined threshold.

[0296] D4. The method of any of D1-D3, further comprising distributing the discharged fuel through a manifold system connected to the fuel port to deliver fuel to multiple destinations.

[0297] D5. The method of any of D1-D4, further comprising adding additional pressurized gas to the gas reservoir during fuel discharge operations to maintain consistent pressure levels throughout fuel expulsion.

[0298] D6. The method of any of D1-D5, wherein maintaining the pressurized gas in a ready state comprises monitoring pressure levels in the gas reservoir using at least one pressure sensor.

[0299] D7. The method of any of D1-D6, wherein filling the flexible bladder comprises introducing fuel through a fuel fill port while venting displaced air through an expansion port.

[0300] D8. The method of any of D1-D7, further comprising regulating fuel flow rate during discharge operations using a regulator positioned along a fuel flow path.

[0301] D9. The method of any of D1-D8, further comprising preventing overpressurization during any of the filling, introducing, maintaining, or discharging steps using at least one relief valve.

[0302] D10. The method of any of D1-D9, wherein the pressurized gas comprises an inert gas selected from the group consisting of nitrogen and compressed air.

[0303] E1. A method of thermal management in a pressurized fuel system, comprising: directing pressurized gas through microchannels formed on at least one surface selected from the group consisting of interior surfaces of a tank and an exterior surface of a bladder positioned within the tank; distributing cooling effects from gas expansion across extended surface areas using the microchannels to prevent localized temperature variations; controlling bladder compression patterns by guiding gas flow along predetermined pathways defined by the microchannels; and managing thermal effects during fuel expulsion operations by balancing cooling from gas expansion against heating from system components.

[0304] E2. The method of E1, wherein directing pressurized gas comprises creating gas flow patterns selected from the group consisting of spiral patterns, axial patterns, longitudinal patterns, and branching patterns.

[0305] E3. The method of any of E1-E2, wherein managing thermal effects comprises counteracting heating effects from a central channel duct extending through a center ofthe tank by positioning the microchannels to create cooling zones around the central channel duct.

[0306] E4. The method of E3, wherein the tank comprises a toroidal configuration defining a central void space, and the central channel duct carries compressed gases or heated fluids through the central void space.

[0307] E5. The method of any of E1-E4, wherein controlling bladder compression patterns comprises creating varying compression zones using microchannels having varying depths and widths to compress different bladder areas at different rates.

[0308] E6. The method of any of E1-E5, wherein the microchannels comprise microstructures selected from the group consisting of grooves, channels, recessed pathways, and dimples.

[0309] E7. The method of any of E1-E6, further comprising maintaining fuel and bladder temperatures within predetermined operating ranges by distributing thermal effects across the microchannels.

[0310] E8. The method of any of E1-E7, wherein distributing cooling effects comprises preventing thermal shock conditions that could compromise bladder material integrity.

[0311] E9. The method of any of E1 -E8, further comprising optimizing fuel expulsion efficiency by ensuring uniform pressure application across bladder surfaces through controlled gas distribution via the microchannels.

[0312] E10. The method of any of E1-E9, wherein the microchannels are formed on both the interior surfaces of the tank and the exterior surface of the bladder to provide enhanced thermal management capabilities.

[0313] F1. A method of controlling a pressurized fuel storage and delivery system using a controller, comprising: receiving pressure data from at least one pressure sensor monitoring system pressure within a gas reservoir and a bladder chamber; determining fuel delivery parameters based on the received pressure data; monitoring fuel flow operations through sensor feedback; and adjusting system operation parameters to maintain predetermined pressure levels and fuel delivery rates based on the fuel delivery parameters and the fuel flow operations.

[0314] F2. The method of F1, further comprising activating a mechanism when the received pressure data indicates that pressure levels exceed a predetermined threshold or in response to a control signal to discharge.

[0315] F3. The method of F2, wherein the mechanism comprises a burst disk configured to rupture at a specific pressure level to initiate fuel delivery.

[0316] F4. The method of any of F1-F3, further comprising controlling a regulator positioned along a fuel flow path to match a target fuel output pressure and flow rate regardless of variations in gas reservoir pressure.

[0317] F5. The method of any of F1-F4, wherein adjusting system operation parameters comprises maintaining constant pressure levels in the gas reservoir throughout fuel delivery operations by controlling introduction of additional pressurized gas.

[0318] F6. The method of any of F1-F5, further comprising providing operational readiness verification by analyzing pressure readings from multiple sensors positioned within different system chambers.

[0319] F7. The method of any of F1-F6, further comprising managing a coupling manifold to control fuel flow distribution to multiple delivery points based on system requirements.

[0320] F8. The method of any of F1-F7, wherein monitoring fuel flow operations comprises receiving real-time data regarding fuel delivery rates and system pressure variations during fuel expulsion.

[0321] F9. The method of any of F1-F8, further comprising implementing safety protocols by monitoring for over-pressurization conditions and activating relief mechanisms when pressure thresholds are exceeded.

[0322] F10. The method of any of F1-F9, further comprising coordinating thermal management operations by controlling gas distribution patterns to balance cooling effects from gas expansion against heating effects from system components.

[0323] G1. A fuel storage and expulsion system comprising: a solid tank made of steel, composite, or other durable materials; a fuel bladder designed to fit within the tank when filled with fuel; an entry port for filling the tank with fuel; an internal fuel tube or castellated interface that prevents the fuel bladder from collapsing over the exit port during fuel expulsion; an exit port connected to a control valve for regulating fuel flow; apressurization system that introduces gas into the tank, exerting pressure on the bladder to expel fuel through the exit port.

[0324] G2. The system of G1, wherein the pressurizing gas is nitrogen or compressed air or other inert compressible gas.

[0325] G3. The system of any of G1-G2, wherein the solid tank and fuel bladder are torus shaped, creating a hollow channel through the center of the fuel apparatus.

[0326] G4. The system of any of G1-G3, wherein solid tank is bifurcated into two sections, one for the fuel bladder to fit snugly when filled against the walls and the second separated through small ports to serve as an air reservoir.

[0327] G5. The system of any of G1-G4, wherein the control valve is either manually operated or automated.

[0328] G6. The system of any of G1-G5, wherein the bladder is made of reinforced elastomers or fuel-resistant polymers.

[0329] G7. The system of any ofGA1-G6, wherein the internal fuel tube is flexible and extends from the base of the tank to the exit port.

[0330] G8. The system of any of G1-G7, wherein the air expansion port includes a oneway valve to prevent air re-entry.

[0331] G9. The system of any of G1 -G8, wherein the solid tank is a flexible mesh, such as Kevlar weave, allowing this fuel apparatus to conform to irregular shapes.

[0332] G10. The system of any of G1 -G9, wherein an air expansion port is used for venting air during fuel filling.

[0333] Other aspects of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

ClaimsWhat is claimed is:

1. A pressurized fuel storage and delivery system, comprising:a tank having interior surfaces defining a fuel storage volume;a flexible bladder positioned within the tank and configured to contain fuel;a gas reservoir positioned within the tank and configured to store pressurized gas;a micro-perforated separator positioned between the gas reservoir and the bladder, the micro-perforated separator configured to allow controlled gas flow from the gas reservoir to a space surrounding the bladder;microchannels formed on at least one surface selected from the group consisting of the interior surfaces of the tank and an exterior surface of the bladder, the microchannels configured to distribute the pressurized gas around the bladder to control bladder compression patterns and manage thermal effects during gas expansion;a pressurization port connected to the gas reservoir and configured to introduce pressurized gas into the gas reservoir; anda fuel port connected to the bladder and configured to allow fuel delivery from the bladder when the pressurized gas compresses the bladder.

2. The pressurized fuel storage and delivery system of claim 1 , wherein the microchannels are configured to distribute cooling effects from gas expansion across extended surface areas to prevent localized temperature drops that could compromise bladder material properties.

3. The pressurized fuel storage and delivery system of claim 2, wherein the tank further comprises a central channel duct extending through a center of the tank, and the microchannels are positioned to create cooling zones around the central channel duct to counteract heating effects from compressed gases flowing through the central channel duct.

4. The pressurized fuel storage and delivery system of claim 1 , wherein the microchannels comprise a pattern selected from the group consisting of spiral patterns, axial patterns, longitudinal patterns, and branching patterns.

5. The pressurized fuel storage and delivery system of claim 4, wherein the spiral patterns create helical gas flow paths around a circumference of the bladder.

6. A fuel storage and delivery apparatus, comprising:a rigid tank configured to contain pressurized components;a flexible bladder positioned within the tank and configured to store liquid fuel, the bladder being constructed from fuel-resistant materials and configured to expand when filled with fuel and contract during fuel expulsion;a pressurized gas system configured to apply pressure to an exterior surface of the bladder to expel fuel from the bladder without mechanical pumps, the pressurized gas system including a gas reservoir and a gas distribution mechanism configured to provide controlled gas flow around the bladder;a fuel interface configured to provide access for introducing fuel into the bladder and for dispensing fuel from the bladder; anda pressurization interface configured to introduce pressurized gas into the gas reservoir.

7. The fuel storage and delivery apparatus of claim 6, wherein the tank comprises a toroidal configuration defining a central void space that allows other components to pass through a center of the tank.

8. The fuel storage and delivery apparatus of claim 7, wherein the central void space accommodates a central channel duct configured to carry compressed gases or heated fluids.

9. The fuel storage and delivery apparatus of claim 7, wherein the tank comprises a dual thread interface including an exterior thread and an interior thread, and a sealing system including a first seal and a second seal positioned to create pressure-tight interfaces between threaded components, so that the gas reservoir and the tank are sealed from an exterior of the apparatus by a cap or by a component connected to the apparatus using force threads to the exterior thread and the interior thread.

10. The fuel storage and delivery apparatus of claim 6, wherein the gas distribution mechanism comprises at least one of a micro-perforated separator or microchannels, wherein the micro-perforated separator is positioned between the gasreservoir and the bladder, and the microchannels are formed on at least one surface selected from the group consisting of interior surfaces of the tank and an exterior surface of the bladder.

11. A pressurized fuel system with safety features, comprising:a tank containing a flexible bladder configured to store fuel;a gas reservoir positioned to provide pressurized gas for fuel expulsion;a pressure-activated mechanism configured to initiate fuel flow when a predetermined pressure threshold is exceeded, the pressure-activated mechanism including a burst disk that ruptures at a specific pressure level to allow fuel delivery; a fuel delivery interface configured to control fuel flow from the bladder; and a pressure control system configured to regulate gas pressure within the system, the pressure control system including at least one safety feature selected from the group consisting of a relief valve configured to prevent over-pressurization and a pressure sensor configured to monitor system pressure.

12. The pressurized fuel system of claim 11 , wherein the burst disk is replaceable and configured to be removed and replaced after activation to enable system reset for subsequent operations.

13. The pressurized fuel system of claim 12, wherein the pressure-activated mechanism further comprises a coupling that provides a replaceable interface for the burst disk and incorporates threading to allow field replacement of the burst disk.

14. The pressurized fuel system of claim 11 , wherein the pressure control system further comprises a controller connected to the pressure sensor and configured to receive pressure data and control fuel delivery operations based on monitored pressure levels.

15. The pressurized fuel system of claim 14, wherein the controller is configured to maintain pressure levels in the gas reservoir throughout fuel delivery operations by controlling introduction of additional pressurized gas.

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