Compressed gas tank system with fast fueling ability at any vessel pressure

1. A method of reducing rupture damage to a liner of a fuel cell tank during fueling with compressed gas comprising:

providing a supply of compressed gas;

providing a storage tank defining the liner therein with a fueling line, and a nozzle in the fueling line, the nozzle movable between at least a flow reduction position and a full fuel flow position;

providing a controller configured to determine a calculated tolerance margin comprising a minimum pressure, a signal tolerance, a degradation and a safety margin;

using the calculated tolerance margin in conjunction with the controller to initiate a low pressure fueling from the supply of compressed gas with the nozzle in the flow reduction position until the minimum pressure of approximately 20 bar within the storage tank is obtained after which the nozzle is moved to the full fuel flow position to deliver a high pressure fueling;

fueling the storage tank from the supply of compressed gas with the nozzle in the full fuel flow position until fueling is completed wherein the initiating of the low pressure reduces a tendency of the liner to rupture through lower impact force between the liner and a surface of the fuel cell tank.

2. The method of claim 1 further comprising initiating fueling from the supply of compressed gas with the nozzle in the flow reduction position and maintaining the nozzle in the flow reduction position until fueling is completed.

3. The method of claim 1 wherein the nozzle is spring loaded.

4. The method of claim 1 wherein the nozzle is powered.

5. The method of claim 1 wherein the nozzle is a proportional flow reduction valve.

6. The method of claim 1 wherein moving the nozzle is controlled by the controller.

7. The method of claim 1 wherein storage tank is in a vehicle and wherein the compressed gas is hydrogen or natural gas.

8. A method of reducing rupture damage to a liner of a fuel cell tank during fueling with compressed gas comprising:

providing a supply of compressed gas;

providing a storage tank defining a liner therein with a fueling line, a nozzle in the fueling line, the nozzle movable between at least a flow reduction position and a full fuel flow position;

providing a controller configured to determine a calculated tolerance margin comprising a minimum pressure, a signal tolerance, a degradation and a safety margin and for controlling the nozzle;

using the calculated tolerance margin in conjunction with the controller to initiate a low pressure fueling from the supply of compressed gas with the nozzle in the flow reduction position until the minimum pressure of approximately 20 bar within the storage tank is obtained after which the nozzle is moved to the full flow position to deliver a high pressure fueling;

determining if a pressure exceeds the minimum pressure;

if the pressure exceeds the minimum pressure, moving the nozzle to the full fuel flow position to deliver a high pressure fueling, and initiating fueling from the supply of compressed gas with the nozzle in the full fuel flow position until fueling is complete;

if the pressure does not exceed the minimum pressure, initiating the low pressure fueling from the supply of compressed gas with the nozzle in the flow reduction position until the minimum pressure is obtained;

when the minimum pressure is obtained, moving the nozzle to the full fuel flow position to deliver the high pressure fueling; and

fueling the storage tank from the supply of compressed gas with the nozzle in the full fuel flow position until fueling is completed wherein initiating the low pressure reduces a tendency of the liner to rupture through lower impact force between the liner and a surface of the fuel cell tank.

9. The method of claim 8 wherein the nozzle is spring loaded.

10. The method of claim 8 wherein the nozzle is powered.

11. The method of claim 8 wherein the nozzle is a proportional flow reduction valve.

12. The method of claim 8 wherein storage tank is in a vehicle and wherein the compressed gas is hydrogen or natural gas.

13. A vehicle fueled by hydrogen to reduce rupture damage to a liner of a fuel tank comprising:

the vehicle having the fuel tank defining the liner therein with a fueling line, a nozzle in the fueling line flow, the nozzle movable between at least a flow reduction position and a full fuel flow position, and a controller configured to determine a calculated tolerance margin comprising a minimum pressure, a signal tolerance, a degradation and a safety margin and for controlling the nozzle wherein the calculated tolerance margin is used in conjunction with the controller to initiate a low pressure fueling from a supply of hydrogen with the nozzle in the flow reduction position until the minimum pressure of approximately 20 bar within the fuel tank is obtained after which the nozzle is moved to the full fuel flow position to deliver a high pressure fueling until fueling is complete wherein the initiating of the low pressure reduces a tendency of the liner to rupture through lower impact force between the liner and a surface of the fuel tank.

14. The vehicle of claim 13 wherein the nozzle is spring loaded.

15. The vehicle of claim 13 wherein the nozzle is a proportional flow reduction valve.

16. The vehicle of claim 13 wherein the fuel tank further comprises an outer layer made of a composite.

17. The vehicle of claim 16 wherein the composite is a carbon fiber matrix and wherein the liner is plastic or aluminum.

18. The vehicle of claim 13 wherein the nozzle is powered.