Adsorbent device

Abstract

The adsorbent material sheet provides enhanced performance in vapor adsorption applications compared to conventional canisters and other emission control devices. The adsorbent material sheet can be formed as part of a small, lightweight canister or can be integrated into a fuel tank. The adsorbent material sheet can also be used as part of an on-board refueling vapor recovery system to control volatile organic compound emissions from the fuel tank of a gasoline vehicle, such as an automobile.

Description

[0001] This application is a divisional application of application No. 201880011319.0, entitled “Adsorbent Device.” Cross-reference to Related Applications: This application claims priority to U.S. Provisional Application No. 62 / 452,704, filed on January 31, 2017, the entire contents of which are incorporated by reference.

[0002] Government Interest: Not Applicable

[0003] Parties to a Joint Research Agreement: Not Applicable

[0004] Incorporation by reference of material submitted on CD-ROM: Not applicable Background technology:

[0005] Evaporative emissions from gasoline and other liquid hydrocarbon fuels are a significant source of air pollution because the various hydrocarbons contained in these fuels form photochemical smog when exposed to sunlight. The compounds of this smog, as well as the hydrocarbons themselves, can cause adverse health effects in humans and animals and cause environmental damage. Evaporative emissions are particularly problematic during vehicle refueling because an "empty" fuel tank is actually full of fuel vapor, and the act of filling the tank with liquid fuel displaces these vapors from the tank. Evaporative emissions are also generated when the fuel within the tank is heated, for example, by hot ambient conditions or by nearby hot exhaust system components. Without controls, fuel vapors are released into the atmosphere as pollutants.

[0006] In the automotive field, gasoline vapors are typically recovered during refueling by an onboard refueling vapor recovery system (ORVR). These devices include multiple components designed to capture displaced vapors from the refueling gasoline and allow the engine to burn them later. The vapors remain sealed within the fuel tank through a specially designed box and fuel filler neck, and excess vapors are captured and adsorbed within a chemical canister. During engine operation, the engine control unit (ECU) allows the adsorbed vapors to be released from the canister and enter the engine fuel system, burning the gasoline vapors as usual and allowing the canister to be used again.

[0007] While ORVR systems have been successful in reducing vapor emissions, they still have drawbacks. Chemical canisters are filled with loose adsorbent particles, such as activated carbon or charcoal, which can be cumbersome to handle and load. These canisters are bulky and heavy because the adsorbent particles cannot physically support themselves, and because strict emissions regulations now prohibit the release of even small amounts of vapor emissions (which requires higher adsorption capacity). Because the adsorbent particles are loose, the canisters are also cumbersome to manufacture, maintain, and handle, and the complexity of the ORVR devices increases the cost of each vehicle while cutting into valuable passenger and cargo space. As automakers demand lighter weight from all components to meet ever-increasing fuel efficiency goals, as well as reduced costs and more passenger and cargo space, there is a need for new ORVR devices that are smaller, lighter, simpler, and more cost-effective while still complying with stricter emissions targets. Summary of the invention:

[0008] In one embodiment, the present invention discloses a sheet of adsorbent material having improved performance compared to an equivalent amount of adsorbent compound provided as a powder.

[0009] In another embodiment, the present invention discloses a sheet of adsorbent material enclosed in a housing.

[0010] In another embodiment, the present invention discloses a sheet of sorbent material that omits the housing and is instead contained directly within the fuel tank.

[0011] In another embodiment, the present invention discloses an emission control system, such as an ORVR, including a sheet of adsorbent material. The sheet of adsorbent material in the ORVR can be enclosed in a housing, or the housing can be omitted.

[0012] The present invention also relates to the following embodiments:

[0013] 1. An adsorbent material sheet product, comprising

[0014] at least two sheets of adsorbent material, wherein each sheet of adsorbent material has a defined upper surface and a lower surface, the upper and lower surfaces having a combined total surface area, and

[0015] wherein each adsorbent material sheet comprises an adsorbent material and a binder, and

[0016] Each sheet of adsorbent material is stacked and arranged such that adjacent upper and lower surfaces of the individual sheets are substantially parallel and aligned to allow fluid to flow at least between the adjacent upper and lower surfaces.

[0017] 2. The adsorbent material sheet product of embodiment 1, wherein the adsorbent material sheet product has a BWC stacking multiplier ratio of about 1.1 to about 1.3, wherein the BWC stacking multiplier ratio is defined by the formula:

[0018] BWC stacking multiplier ratio = [(measured BWC of the entire adsorbent material sheet product) / (measured BWC of an individual adsorbent material sheet outside the product)] / number of adsorbent material sheets in the adsorbent material sheet product.

[0019] 3. The adsorbent material sheet product of embodiment 1, wherein an independently measured individual adsorbent material sheet has a BWC value that is 5% to 15% higher than the BWC of the same weight of adsorbent material in pelletized or powdered form.

[0020] 4. The adsorbent material sheet product of embodiment 1, wherein at least one of the adsorbent material sheets is configured to be flat, spirally cylindrically wound, elliptical wound, elongated rectangular rod wound, folded, "S"-shaped laminated, formed into concentric cylinders, formed into concentric ellipses, formed into concentric rectangular rods, or a combination thereof.

[0021] 5. The adsorbent material sheet product of embodiment 1, wherein at least one of the adsorbent material sheets has raised and / or recessed portions.

[0022] 6. The adsorbent material sheet product of embodiment 5, wherein the raised and / or recessed portions are present on adjacent sheets and are embedded.

[0023] 7. The sorbent material sheet product of embodiment 5, wherein the raised and / or recessed portions are present on adjacent sheets and are not embedded.

[0024] 8. The sorbent material sheet product of embodiment 1, wherein the sorbent material sheet product has a void volume of about 10% or less.

[0025] 9. The adsorbent material sheet product of embodiment 1, wherein each individual adsorbent material sheet has a density of about 0.08 g / cc to about 1.5 g / cc.

[0026] 10. The sorbent material sheet product of embodiment 1, wherein the sorbent material sheet product has a BWC greater than about 10 g / 100 cc.

[0027] 11. The adsorbent material product of embodiment 1, wherein the adsorbent material sheet product has a BWC of about 7.0 g / 100 cc to about 30 g / 100 cc.

[0028] 12. The adsorbent material sheet product of embodiment 1, wherein the adsorbent material sheet comprises adsorbent material particles having at least two populations having different average particle sizes, and wherein the average particle sizes of the two populations have a ratio of about 1:2 to about 1:10.

[0029] 13. The adsorbent material sheet product of embodiment 1, wherein the amount of binder and the amount of adsorbent material sheet product are present in a gradient such that the amount of binder is highest on the exterior of the adsorbent material sheet product and the amount of binder is lowest on the interior of the adsorbent material sheet product.

[0030] 14. The sorbent material sheet product of embodiment 1, wherein at least one sorbent material sheet comprises holes, cutouts, or openings.

[0031] 15. The adsorbent material sheet product of embodiment 1, wherein the binder comprises polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

[0032] 16. A wound adsorbent material sheet product comprising:

[0033] a sheet of adsorbent material defining an upper surface and a lower surface and having a total surface area, and comprising an adsorbent material and a binder,

[0034] The adsorbent material sheets are spirally wound to form adjacent sheets that allow fluid to flow around and between adjacent sheets.

[0035] 17. The coiled sorbent material sheet product of embodiment 16, wherein the sorbent material sheet in its coiled form has a BWC that is at least 10% higher than the BWC of the same sorbent material sheet in its unrolled form.

[0036] 18. The coiled adsorbent material sheet product of embodiment 16, wherein the coiled adsorbent material sheet product has a BWC that is at least 10% higher than the BWC of a pelletized or powdered form of substantially the same amount of adsorbent material in the adsorbent sheet.

[0037] 19. The coiled sorbent material sheet product of embodiment 16, wherein the coiled sorbent material sheet product has a generally cylindrical shape having a length greater than its diameter.

[0038] 20. The wound adsorbent material sheet product of embodiment 16, wherein the wound adsorbent material sheet product is wound to a pressure of 500-700 kg / m 3 The average roll density (average roll density).

[0039] 21. The wound adsorbent material sheet product of embodiment 16, wherein the wound adsorbent material sheet product has a butane working capacity greater than about 10 g / 100 cc.

[0040] 22. The wound adsorbent material sheet product of embodiment 16, wherein the wound adsorbent material sheet product has a butane working capacity of about 7.0 g / 100 cc to about 30 g / 100 cc.

[0041] 23. The coiled adsorbent material sheet product of embodiment 16, wherein the coiled adsorbent material sheet comprises at least two populations of adsorbent material particles, wherein each of the at least two populations has a different average particle size.

[0042] 24. The wound adsorbent material sheet product of embodiment 16, wherein the wound adsorbent material sheet comprises adsorbent material particles having at least two populations having different average particle sizes, and wherein the average particle sizes of the two populations have a ratio of about 1:2 to about 1:10.

[0043] 25. The wound adsorbent material sheet product of embodiment 16, wherein the binder comprises polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylate, UV-curable methacrylate, thermally curable divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low density and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

[0044] 26. A vapor adsorption canister comprising:

[0045] The adsorbent material sheet product as described in Example 1, and

[0046] A housing at least partially enclosing a sheet of adsorbent material product as described in Example 1.

[0047] 27. The vapor adsorption canister of embodiment 26, wherein the shell is flexible.

[0048] 28. The vapor adsorption canister of embodiment 26, wherein the shell comprises polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamides, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

[0049] 29. The vapor adsorption canister of embodiment 26, wherein the shape of the shell substantially conforms to the shape of the enclosed adsorbent material sheet product of embodiment 1.

[0050] 30. The vapor adsorption canister of embodiment 26, further comprising: at least one structure selected from the group consisting of a tube, an inlet, an outlet, a sensor, a valve, and a fluid channel.

[0051] 31. A vapor adsorption canister comprising:

[0052] a. a wound adsorbent material sheet product as described in Example 16, and

[0053] b. A housing at least partially enclosing the rolled adsorbent material sheet product as described in Example 16.

[0054] 32. The vapor absorber canister of embodiment 31, wherein the shell is flexible.

[0055] 33. The vapor adsorption canister of embodiment 31, wherein the shell comprises polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamides, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

[0056] 34. The vapor absorber canister of embodiment 31, wherein the shell is shaped to substantially conform to the shape of the enclosed rolled sheet of adsorbent material product of embodiment 16.

[0057] 35. The vapor adsorption canister of embodiment 31, further comprising at least one structure selected from the group consisting of a tube, an inlet, an outlet, a sensor, a valve, and a fluid channel.

[0058] 36. A box with integrated vapor adsorption, the box comprising:

[0059] box structure, and

[0060] at least one sheet of adsorbent material having a defined upper surface and a lower surface, the upper and lower surfaces having a combined total surface area, and

[0061] wherein each adsorbent material sheet comprises an adsorbent material and a binder, and

[0062] At least one fastening means for fastening the sheet of adsorbent material to a surface of the tank that is not regularly immersed in the volatile liquid contained within the tank.

[0063] 37. The box with integrated vapor adsorption of embodiment 36, wherein the fastening means is an adhesive layer formed between one surface of the sheet of adsorbent material and a wall of the box.

[0064] 38. A box with integrated vapor adsorption as described in Example 36, wherein the adhesive includes at least one of pressure-sensitive adhesives, UV-curing adhesives, heat-curing adhesives, hot melt adhesives, reactive multi-component adhesives, acrylic and (meth)acrylic adhesives, acrylate and (meth)acrylate adhesives, epoxy adhesives in one-component or two-component preparations, urethane adhesives, and their copolymers and combinations.

[0065] 39. The tank with integrated vapor adsorption as described in embodiment 36, wherein the tank further includes at least one fuel pump, fuel delivery line, fuel return line, atmospheric vent line, port, valve, sensor, air inlet, open cell foam, baffle, bladder and combination thereof.

[0066] 40. The tank with integrated vapor adsorption of embodiment 36, wherein the tank is a fuel tank having a "ship in a bottle" configuration.

[0067] 41. An on-vehicle supplemental fuel vapor recovery device comprising the adsorbent material sheet product of embodiment 1.

[0068] 42. An on-vehicle supplemental fuel vapor recovery device comprising the wound adsorbent material sheet product of embodiment 16.

[0069] 43. An on-vehicle refueling vapor recovery device comprising the vapor adsorption canister of Example 26.

[0070] 44. An on-vehicle refueling vapor recovery device comprising the vapor adsorption canister of Example 31.

[0071] 45. An on-vehicle refueling vapor recovery device comprising the tank with integrated vapor adsorption as described in Example 36.

[0072] Description of the drawings: Not applicable. Specific implementation method:

[0073] Before describing the compositions and methods of the present invention, it should be understood that the present invention is not limited to the specific processes, compositions or methods described, as these may vary. It should also be understood that the terms used in the description are only for the purpose of describing specific types or embodiments and are not intended to limit the scope of the invention, which will be limited only by the appended claims. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present invention, preferred methods, devices and materials are now described. All disclosures mentioned herein are incorporated by reference in their entirety. No provision herein shall be construed as allowing the present invention to be disclosed without authorization by prior invention.

[0074] It must also be noted that, as used herein and in the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a combustion chamber" refers to "one or more combustion chambers" and equivalents thereof known to those skilled in the art, and so forth.

[0075] As used herein, the term "about" means plus or minus 10% of the numerical value of the number with which it is used. Thus, about 50% means within the range of 45%-55%.

[0076] As used herein, the term "adsorbent material" is intended to encompass all known materials from any source that are capable of adsorbing liquids and / or gases. For example, adsorbent materials include, but are not limited to, activated carbon, natural and synthetic zeolites, silica, silica gel, alumina, zirconia, and diatomaceous earth.

[0077] As used herein, the term "may" means that the subsequently listed elements may or may not be included in the embodiment. For example, an embodiment that may include a polymer substrate means that the embodiment may include the polymer substrate, but it is also contemplated that the embodiment may not include the polymer substrate.

[0078] As used herein, descriptions and claims of multiple sheets of adsorbent material mean that there are multiple separate sheets with sides and / or surfaces proximate to one another. Alternatively, descriptions and claims of multiple sheets of adsorbent material mean that there is only a single sheet, but that it has been wrapped or folded upon itself to create a stack of stacked, wrapped, or otherwise configured sheets with sides and / or surfaces proximate to one another. The term also contemplates that multiple sheets are stacked together and then wrapped or otherwise folded to form alternating layers in a single stack.

[0079] Embodiments of the present invention relate to devices containing one or more sheets of adsorbent material, adsorbent material sheets, methods for preparing adsorbent material sheets, and devices containing such sheets. In various embodiments, the adsorbent material sheet can be composed of an adsorbent material and a binder and have a thickness of less than about 1 mm. Devices in various embodiments can include a housing and one or more sheets of adsorbent material. In some embodiments, the device can have a void fraction of about 10% or more of the total volume of the housing.

[0080] Adsorbent material sheet

[0081] The adsorbent material sheet of the present invention may include any of the above-mentioned adsorbent materials, including but not limited to activated carbon, natural and synthetic zeolites, silica, silica gel, alumina, zirconia, and diatomaceous earth. In certain embodiments, the adsorbent material sheet may be composed of activated carbon. The adsorbents may be used alone or in combination.

[0082] Activated carbon can have different grades and types selected based on performance requirements, cost and other considerations. Activated carbon can be from particles that are reagglomerated from powders, from particles that are crushed or sized from nut shells, wood, coal, or pellets produced by extrusion, or in powdered form. Activated carbon can be formed by a process of carbonization and activation. The raw materials (e.g., wood, nut shells, coal, asphalt, etc.) are oxidized and devolatilized, wherein steam and / or carbon dioxide are gasified to form a pore structure in the activated carbon that can be used for adsorption. The initial oxidation and devolatilization process can include chemical treatment with dehydration chemicals (e.g., phosphoric acid, sulfuric acid, sodium hydroxide, potassium hydroxide, and combinations thereof).

[0083] Various activation methods are known in the art. The most useful method for providing activated carbon for the adsorbent material sheets of the claimed invention involves the steps of providing wood and / or wood byproducts, acid-treating the wood and / or wood byproducts by exposure to phosphoric acid, and carbonizing the wood and / or wood byproducts using steam and / or carbon dioxide gasification. This method produces activated carbon particles with the highest butane working capacity ("BWC"), a measure of activated carbon performance. Further details of BWC testing and results are described in the Examples.

[0084] Activated carbon can be formed from materials including bagasse, bamboo, coconut shells, peat, wood in the form of sawdust and waste such as hardwood and softwood sources, lignite, coal and coal tar, petroleum pitch, asphalt and earth pitch, corn stover and hulls, wheat straw, spent grains, rice hulls and bran, nut shells, and combinations thereof.

[0085] The adsorbent material sheet may further comprise one or more adhesives. The embodiments are not limited to a particular adhesive, and the adhesive may comprise polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers such as perfluoroelastomers (FFKM) and tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers such as para-aromatic polyamide polymers and meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof. The adhesive may be thermoplastic or thermosetting as desired, and may comprise a mixture of thermoplastic and thermosetting compounds.

[0086] The amount of binder can be from about 2% to about 30% by weight of the total composition, and in certain embodiments, the amount of binder can be from about 2% to about 20% by weight or from about 2% to about 10% by weight of the total composition, or any individual amount or range encompassing these example amounts. In some embodiments, the adsorbent material sheet may include a solvent, which can typically be present in a small residual amount, such as less than 10%, less than 5%, or less than 2% by weight and greater than about 0.1% or 0.2%. In particular, in some embodiments, the adsorbent material sheet may be free of (0%) solvent.

[0087] In some embodiments, the adsorbent material sheet may have a thickness of less than about 1 mm, about 0.01 mm to about 1.0 mm, about 0.02 mm to about 0.90 mm, about 0.05 to about 0.95 mm, about 0.05 to about 0.90 mm, or any individual thickness or range encompassed by these example ranges. The adsorbent material sheet of various embodiments may have a density of about 0.05 g / cc to about 2.0 g / cc as measured by the Particle Density Test, and in other embodiments, the adsorbent material sheet may have a density of 0.08 g / cc to about 1.5 g / cc, about 0.1 g / cc to about 1.3 g / cc as measured by the Particle Density Test, or any density or range encompassed by these example ranges. In some embodiments, the adsorbent material sheet may have a resistivity of less than 20 ohm-cm, and in certain embodiments, the adsorbent material sheet may have a resistivity of about 10 ohm-cm to about 20 ohm-cm, about 8 ohm-cm to about 18 ohm-cm, or any individual resistivity or range encompassed by these example ranges. The BWC of each sheet of adsorbent material may be greater than about 10 g / 100cc, and in some embodiments, the BWC may be from about 7.0 g / 100cc to about 30 g / 100cc, about 8.0 g / 100cc to about 25 g / 100cc, about 10 g / 100cc to about 20 g / 100cc, about 10 g / 100cc to about 15 g / 100cc, about 11 g / 100cc to about 15 g / 100cc, about 12 g / 100cc to about 15 g / 100cc, or any individual BWC or range encompassed by these example ranges. In other examples, the BWC can be about 9 g / 100cc to about 15 g / 100cc, about 12 g / 100cc to about 20 g / 100cc, about 13 g / 100cc to about 20 g / 100cc, about 14 g / 100cc to about 20 g / 100cc, or about 15 g / 100cc to about 20 g / 100cc. It is also contemplated that any endpoints of the above-recited ranges can be combined to form new and different ranges.

[0088] The adsorbent material sheets of the present invention have performance as measured by BWC that is higher than conventional adsorbent materials provided in powder or other particulate form.

[0089] The adsorbent material sheet of the embodiment can be prepared by any method. In some embodiments, the adsorbent material sheet can be prepared by crushing the granular or pelletized adsorbent material into a powder, mixing the powder with a binder to form a mixture, heating and blending the mixture, and rolling the mixture to form the adsorbent material sheet. The crushing step can produce adsorbent particles having the following average particle size: about 0.001 mm to about 0.2 mm, about 0.005 mm to about 0.1 mm, about 0.01 mm to about 0.075 mm, or any independent particle size or range encompassed by these example ranges, and in certain embodiments, the crushed adsorbent particles may have an average particle size of about 0.001 mm to about 0.01 mm. The step of mixing the powder with the binder may include mixing the adsorbent particle powder with about 2% to about 20% by weight or about 2% to about 10% by weight of the total composition, or any independent amount or range encompassed by these example ranges. Heating can be carried out at any temperature sufficient to remove residual solvent (e.g., about 50° C. to about 200° C.).

[0090] The adsorbent material sheets of the present invention can include different distributions of particles of different sizes to improve the packing efficiency of the powder within the adsorbent material sheet. Selecting particles of different sizes can also improve the rheological properties of the powder and the surrounding binder, which allows for improved mixing and uniform particle distribution prior to forming the adsorbent material sheet. In some embodiments, the particles of the adsorbent material sheet can have a single particle size distribution, while in other embodiments, the particles can have two different particle size distributions. In further embodiments, the particles can have at least three different particle size distributions.

[0091] The average particle sizes of at least two different particle populations, each having a specific size distribution, can be selected such that the average particle sizes have a ratio between about 1:1 and about 1:15. In other embodiments, the average particle sizes of the two different particle populations can have a ratio between about 1:2 and about 1:10. The average particle sizes can also have a ratio between about 1:2 and about 1:5, or any combination of the ratios listed above.

[0092] For a given volume and weight, the adsorbent material sheet has a significantly higher adsorption capacity than prior art fuel vapor recovery canisters. This capacity can be utilized in a variety of ways. In some embodiments, the adsorbent material sheet can provide enhanced pollution control in jurisdictions that require such high levels of control. In other embodiments, the overall size, cost, and weight of the ORVR can be reduced for a specific performance level. In further embodiments, an ORVR adsorption device can be designed that has enhanced performance over conventional adsorption canisters, allowing designers to omit expensive and complex returnless fuel pump systems (which would otherwise be required to reduce evaporative emissions). Higher performance adsorption devices can also make active condensing vapor systems unnecessary, which avoids the size, weight, and cost of compressor pumps and condensate storage tanks. However, it should be understood that ORVR adsorption devices using the adsorbent material sheet of the present invention can also be combined with these devices to achieve exceptionally higher performance than conventional systems with minimal size, weight, and cost penalties.

[0093] The sheets of adsorbent material can be configured together in a variety of ways, depending on the physical space that the sheets of adsorbent material must fit into, the desired device performance, and the features to be included near the sheets. In some embodiments, the sheets can be corrugated, include folds, and / or include holes or openings to increase the surface area of ​​the sheet of adsorbent material exposed to the passing fluid, thereby increasing the performance of a given total sheet surface area. The various corrugations, folds, holes, and openings can also be manufactured to a certain size and positioned to open up internal and external features (such as fluid channels, tubes, sensors, and valves). The folds of the sheets of adsorbent material can take a variety of forms, such as a spiral wrap configuration that is cylindrical or elliptical. The folds can also be in the form of an "S" shape, or a convex or concave "C" shape, depending on the desired device size and / or any other desired internal or external features. The sheets of adsorbent material can also be stacked in a flat or curved configuration, and the stacked sheets can be square, rectangular, circular, elliptical, or other irregular shapes as needed to fit the intended space. This, combined with the housing features discussed below, enables devices formed from sheets of sorbent material to fit in smaller, more irregularly shaped spaces than prior art canister devices, which maximizes vehicle interior space.

[0094] In addition to the above-described configurations, the adsorbent material sheets may also have surface features. In some embodiments, the adsorbent material sheets may include raised portions, and in other embodiments, the adsorbent material sheets may include recessed portions. These surface features may be combined within the same sheet. Including raised and / or recessed portions in a sheet may be used to form various configurations between sheets when the sheets are stacked, wrapped, and the like. For example, the sheets may be aligned so that the raised and / or recessed portions are embedded in one another, which brings adjacent sheets closer together. The sheets may also be aligned so that the raised and / or recessed portions are not embedded in one another, which creates gaps between adjacent sheets. The alignment may be used to form various open and closed channels for vapor adsorption between the sheets.

[0095] Adsorbent material sheet products

[0096] The above-described adsorbent material sheets are combined into an adsorbent material sheet product. The combination of adsorbent material sheets utilizes one or more of the above-described characteristics, such as increased surface area to volume ratio, reduced void space, improved adsorbent performance, etc. Generally, individual adsorbent material sheets are arranged adjacent to one another to form an adsorbent material sheet product, which includes stacked, rolled, wound, folded, and / or laminated sheets such that surfaces of the adsorbent material sheets are in close proximity or adjacent to one another. Regardless of the arrangement, the goal is to maximize the surface area of ​​the sheet exposed to the vapor, fluid, and / or gas flow, and thereby maximize the performance of the adsorbent material sheet.

[0097] Stacked adsorbent material sheet product: The stacked adsorbent material sheet product of the present invention comprises two or more adsorbent sheets, each adsorbent sheet defining an upper surface and a lower surface and having a known combined total surface area, wherein each adsorbent sheet comprises adsorbent material and a binder; wherein adjacent adsorbent sheets are stacked and arranged so that the adjacent upper and lower surfaces are substantially coincident with each other and are aligned to allow fluid to flow at least between the adjacent upper and lower surfaces.

[0098] This arrangement results in an improved BWC. For example, each individual sheet of adsorbent material may have a BWC of about 12, and the stacked adsorbent sheet media has a BWC that is at least about 1%-10%, at least about 5%-15%, at least about 2%-20%, at least about 5%-10%, or at least about 7% higher than the sum of the BWCs of the individual sheets. The stacked adsorbent sheet product has a BWC that is at least about 5% higher than the BWC of an unstacked sheet of the same known surface area.

[0099] The performance improvement of the stacked adsorbent material sheet products of the present invention can also be measured as the performance of a product having a given amount of activated carbon compared to the performance of the same amount and grade of activated carbon if provided in pelletized or powdered form in a canister. In some embodiments, the stacked adsorbent sheet products have a BWC that is about 3% higher, about 5% higher, about 7% higher, about 9% higher, about 10% higher, about 12% higher, about 14% higher, and about 16% higher than the same amount and grade of activated carbon in pelletized or powdered form in a canister. Ranges based on these amounts are also contemplated, such as between about 5% and 14% higher, between about 5% and 10% higher, about 10% higher, and about 16% higher. - 16% among other performances.

[0100] It should be noted that these improvements are only as measured between the weight of pelletized or powdered activated carbon and the stacked adsorbent material sheet product, and do not account for other improvements in the stacked adsorbent material sheet product. A key difference described above is the omission of the rigid canister that would otherwise be required. The omission of the rigid canister required in prior art systems involving pelletized or powdered activated carbon, which is required because the loose activated carbon cannot support itself, further drives weight reduction and, therefore, even further improves performance for a given weight.

[0101] The stacked adsorbent sheet product has a BWC that is at least 10% higher than the BWC of a pelletized / powdered form of the same amount of adsorbent material by weight in the adsorbent sheet. The stacked adsorbent sheet product has a butane working capacity greater than about 10 g / 100 cc. The stacked adsorbent sheet product has a butane working capacity of about 7.0 g / 100 cc to about 30 g / 100 cc, or greater than about 12 g / 100 cc, or greater than about 13 g / 100 cc, or greater than about 14 g / 100 cc, or greater than about 15 g / 100 cc, or greater than 20 g / 100 cc. Ranges such as about 10-20 g / cc, about 10-12 g / cc, about 10-14 g / cc, about 12-14 g / cc, about 12-15 g / cc, and about 15-20 g / cc are also contemplated.

[0102] In some embodiments, the stacked sheets are maintained in a spaced relationship that controls one or more of the void volume, flow rate, pressure drop, and other properties. In some embodiments, such spacing is achieved where at least one of the two or more sheets of adsorbent material is corrugated. Spacing can also be achieved using various flaps in the sheets, and can also be achieved by corresponding raised and / or recessed portions of the sheets that align to form gaps between the sheets. If the sheets are intentionally arranged so that the raised and / or recessed portions of the sheets are not embedded between the sheets, this results in additional spacing between the sheets and allows fluid to flow in those portions. If the sheets are intentionally arranged so that at least some of the raised and / or recessed portions are embedded between the sheets, this results in a more tightly packed stack of sheets and reduces the spacing between the sheets, correspondingly reducing or even stopping fluid flow. A combination of these features can be used to form a stacked adsorbent sheet product having directional areas or channels for fluid flow and barriers or edge seals for preventing fluid leakage. These features for fluid flow can also include holes, cutouts, or openings through one or more sheets in the stacked adsorbent sheet product.

[0103] Each adsorbent sheet defines opposite side edges (which are substantially parallel to the fluid flow). The coincident side edges of adjacent adsorbent sheets can be separated from one another, joined together, or some combination thereof. In this manner, the edges of the stacked adsorbent material sheet product can be sealed, partially sealed, or unsealed. The nature of the sealing or unsealing can be selected to achieve a desired result, such as changing the fluid flow rate and / or pattern or other characteristics.

[0104] In some embodiments, the stacked adsorbent material product produces a void volume of about 10% or less, in some embodiments, a void volume of about 8% or less, in some embodiments, a void volume of about 6% or less, and in some embodiments, a void volume of about 4% or less.

[0105] In some embodiments, each sorbent sheet has a density of about 0.08 g / cc to about 1.5 g / cc.

[0106] In some cases, the adsorbent material sheet product includes at least two populations of adsorbent material particles, wherein each of the at least two populations has a different average particle size. See the description of bimodal particle size distribution discussed above with respect to a standalone adsorbent material sheet. With respect to products formed from multiple adsorbent material sheets, the same distribution ratios between the adsorbent particle populations are contemplated. In some cases, the density of adsorbent material particles achieved by the at least two populations is greater than the density achieved by either population alone. Inclusion of a bimodal particle size distribution can also be used to improve the mechanical properties of the adsorbent material sheet product by making the polymer sheet more resistant to shear forces.

[0107] In some cases, the adsorbent material sheet product includes at least two adsorbent material sheets, each of which has a defined upper surface and a lower surface, the upper and lower surfaces having a combined total surface area, and wherein each adsorbent material sheet comprises an adsorbent material and a binder, and wherein each adsorbent material sheet is stacked and arranged such that adjacent upper and lower surfaces of the individual sheets are substantially parallel and aligned to allow fluid to flow at least between the adjacent upper and lower surfaces.

[0108] The adsorbent material sheet product may have a BWC stacking multiplier ratio of about 2.0, where the BWC stacking multiplier ratio is defined by the following formula:

[0109] BWC stacking multiplier ratio = [(measured BWC of the entire adsorbent material sheet product) / (measured BWC of an individual adsorbent material sheet outside the product)] / number of adsorbent material sheets in the adsorbent material sheet product.

[0110] The BWC stacking multiplier ratio can be at least about 1.0, at least about 1.1, at least about 1.2, at least about 1.3, at least about 1.4, at least about 1.5, at least about 1.6, at least about 1.7, at least about 1.8, at least about 1.9, at least about 2.0, at least about 2.1, at least about 2.2, at least about 2.3, at least about 2.4, at least about 2.5, at least about 2.6, at least about 2.7, at least about 2.8, at least about 2.9, and at least about 3.0. Additionally, endpoints can be combined, for example, from about 1.0 to 1.5, from about 1.1 to 1.2, from about 1.1 to 1.3, from about 1.5 to 2.0, from about 2.0 to 2.5, and from about 2.5 to 3.0.

[0111] An adsorbent material sheet product, wherein the adsorbent material sheet product has a BWC value that is about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, and about 50% higher than the BWC of the same weight of adsorbent material in pelletized or powdered form. These values ​​can also be combined to form ranges, for example, between about 5% and 25% higher. The present invention also contemplates that these values ​​are endpoints of a range, for example, at least about 40% higher.

[0112] The adsorbent material sheets in the adsorbent material sheet product may be configured as flat, spirally cylindrically wound, elliptical wound, elongated rectangular rod wound, folded, "S" shaped laminated, formed into concentric cylinders, formed into concentric ellipses, formed into concentric rectangular rods, or a combination of these forms.

[0113] In some embodiments, the adsorbent material sheet product will comprise a single adsorbent material sheet that is wound or coiled to achieve desired characteristics including, but not limited to, density, void space, pressure drop, and the like.

[0114] Wound / coiled adsorbent material sheet products: As an alternative to or in combination with stacked embodiments, adsorbent material sheet products can also be wound or coiled. Wound or coiled adsorbent material sheet products include an adsorbent sheet defining an upper surface and a lower surface and having a known combined total surface area, wherein the adsorbent sheet includes an adsorbent material and a binder, wherein the adsorbent sheet is spirally wound to create adjacent sheet layers that allow fluid to flow around and between the adjacent sheet layers.

[0115] Similar to the stacked sheet arrangement, the wound sorbent sheet product has improved performance relative to individual sheets of sorbent material and relative to an equivalent weight of activated carbon provided in pelletized or powdered form.

[0116] For a given sheet area, the coiled arrangement produces an improved BWC compared to the same area of ​​an uncoiled individual sheet. For example, each individual sheet of adsorbent material may have a BWC of about 12, and the coiled adsorbent sheet media may have a BWC that is at least about 1%-10%, at least about 5%-15%, at least about 2%-20%, at least about 5%-10%, at least about 5%, or at least about 7% higher than the sum of the BWCs of the individual sheets.

[0117] The improved performance of the wound adsorbent material sheet products of the present invention can also be measured as the performance of a product having a given amount of activated carbon compared to the performance of the same amount and grade of activated carbon if provided in a canister in pelletized or powdered form. In some embodiments, the wound adsorbent sheet products have a BWC that is about 3% higher, about 5% higher, about 7% higher, about 9% higher, about 10% higher, about 12% higher, about 14% higher, and about 16% higher than the same amount and grade of activated carbon in pelletized or powdered form in a canister. Performance ranges based on these amounts are also contemplated, such as between about 5% and 14% higher, between about 5% and 10% higher, between about 10% and 16% higher, and so forth.

[0118] The wound adsorbent sheet product has a BWC that is at least 10% higher than the BWC of a pelletized / powdered form of the same amount of adsorbent material by weight in the adsorbent sheet. The stacked adsorbent sheet product has a butane working capacity greater than about 10 g / 100 cc. The stacked adsorbent sheet product has a butane working capacity of about 7.0 g / 100 cc to about 30 g / 100 cc, or greater than about 12 g / 100 cc, or greater than about 13 g / 100 cc, or greater than about 14 g / 100 cc, or greater than about 15 g / 100 cc, or greater than 20 g / 100 cc. Ranges such as about 10-20 g / cc, about 10-12 g / cc, about 10-14 g / cc, about 12-14 g / cc, about 12-15 g / cc, and about 15-20 g / cc are also contemplated.

[0119] The wound sorbent sheet products as described herein have a generally cylindrical shape (having a length significantly greater than its diameter), but may take on any dimensions, including conical or frustoconical variations, as well as ellipsoidal or other shapes.

[0120] The density of the wound sorbent sheet product can be calculated based on the following formula:

[0121]

[0122] The wound adsorbent sheet product can be wound into about 80-1500kg / m 3 , about 500-2000kg / m 3 , about 750-1500kg / m 3 , about 900-1200kg / m 3 , about 900-1050kg / m 3 , about 400-500kg / m 3 , about 500-600kg / m 3 , about 500-550kg / m 3 , about 600-650kg / m 3 , about 650-700kg / m 3 , and about 700-750kg / m 3 The average volume density.

[0123] The wound adsorbent sheet product has a butane working capacity greater than about 10 g / 100 cc. In some embodiments, the wound adsorbent sheet product has a butane working capacity of about 7.0 g / 100 cc to about 30 g / 100 cc. The wound adsorbent sheet product may also have the same butane working capacity as the unwound adsorbent sheet product described above.

[0124] Similar to the discussion above regarding stacked sheets of adsorbent material, wound or coiled sheets of adsorbent material can include multiple particle size distributions or populations of granular or powdered activated carbon adsorbent. The same ratios are considered as discussed above. Similar to the discussion above, this results in higher performance because it enables a greater amount of activated carbon to be incorporated into the sheet forming the coiled adsorbent sheet product.

[0125] As used herein, a wound or coiled adsorbent sheet product refers to any form of layering of one or more adsorbent material sheets by winding, spiral winding, concentric layering of tubes (having any cross-sectional shape, such as circular, elliptical, square, triangular, rectangular, etc.), or a combination thereof. For example, a single adsorbent material sheet can be spirally wound along its length to form a cylindrically wound adsorbent material sheet product. As another example, multiple adsorbent material sheets can be stacked and then wound together to form a similar cylindrical shape. As another alternative, several sheets can be arranged, each forming a cylinder having a slightly different diameter from the next sheet, so that they form concentric rings with the cross-section of cylinders of similar size. Different combinations of these and other arrangements can be used to fill spaces within shells or tanks of any shape, as described elsewhere herein.

[0126] As described above with respect to the sheet of adsorbent material, the binder is selected from polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

[0127] case

[0128] The present invention also contemplates the use of a housing that partially or completely encapsulates a sheet of adsorbent material. The housing can be constructed in a variety of shapes, such as tetrahedrons, cubes and cube-like shapes, cylinders, spheres, monolithic hyperboloids, cones, ellipses, rectangles, hyperbolic paraboloids, elongated rods, parabolas, and combinations of these shapes. Combinations can be selected to have different sections, each of which has a different shape or portions of different shapes. The housing can also include sections that are separate and connected by additional components, such as at least one hose or tube (designed to transfer fuel vapor as needed), or a thin portion of the housing that contains the sheet of adsorbent material. The housing can also be constructed without a shape, such as as a flexible bag or pouch that contains the sheet of adsorbent material.

[0129] A major advantage of the present invention is the use of sheets of adsorbent material that are both flexible and self-supporting and can be laminated, rolled, wrapped, folded, or stacked in a variety of configurations within the housing to accommodate varying mechanical requirements within the tight confines of a vehicle. In such embodiments, the housing will be designed to conform to or fit within the space available for the device to be stored. For example, the housing can be sized and shaped to fit within or around a wheel well, a drive shaft, a battery for a hybrid powertrain, a spare tire, a tire changing kit, a tire repair kit, a vehicle trunk or other storage space, a vehicle bumper and body panels, an exhaust system, other emission control equipment such as urea or other injection tanks, fuel lines, a vehicle frame, suspension components, an engine compartment, under a passenger compartment seat, within a passenger compartment seat, and other spaces that are too small or too difficult to reach for efficient use as passenger or cargo space.

[0130] To further reduce weight and size and utilize a self-supporting sheet of adsorbent material, the housing can be in the form of a thin-walled bag or pouch. This is possible because the adsorbent material sheet has some mechanical structure and is self-supporting, and therefore does not require a rigid outer container as in conventional canisters. The film material forming the bag can have a thickness of about 10 μm to about 250 μm. In other embodiments, the bag film can have a thickness of about 20 μm to about 175 μm, and the bag film can have a thickness of about 50 μm to about 125 μm.

[0131] The bag or pouch may be formed from any material used in fuel systems, and in particular from a material designed to withstand the chemical action of the contained fuel vapor. Bag materials include polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, heat-curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers such as perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers such as para-aromatic polyamide polymers and meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof. The bag is typically thermoplastic to provide flexibility, but may also be combined with an amount of thermoset plastic, or may be in the form of a cured rubber or elastomer.

[0132] The housing, bag or pouch can also be designed to act as a vapor barrier to adsorbed fuel vapor contained therein. This barrier property can be inherent in the polymer itself or can be achieved through the use of at least one barrier additive and / or at least one barrier layer. Examples of barrier additives that can be formed as a layer or particulate filler include polymers such as epoxies, polyamides, polyamideimides, fluoropolymers, fluororubbers, and combinations thereof. The barrier layer can also be made of metals such as aluminum, steel, titanium, and alloys thereof. The metal barrier layers can be formed by conventional mechanical means, such as co-extrusion or adhesion with other layers of the housing, or they can be chemically deposited, such as by chemical vapor deposition or electroplating. The metal barrier layer can be formed from a foil having a thickness of less than about 25 μm, less than about 20 μm, less than about 15 μm, less than about 10 μm, or less than about 5 μm.

[0133] The housing and its materials can also be selected to be compatible with "ship-in-a-bottle" fuel systems. In such systems, many or all fuel system components, including the fuel pump, ORVR, fuel filter, valves, and other components, are assembled within the vehicle's fuel tank. Such systems are advantageous because they reduce the amount of assembly time and space required for the fuel system. In such systems, the housing should be comprised of a material that can withstand immersion in the selected fuel (typically gasoline) within the vehicle's fuel tank for extended periods of time while also withstanding the effects of adsorbed fuel vapors therein.

[0134] The housing can also be a thin metal housing. The thin metal housing can be formed from flexible or rigid metals, such as steel, aluminum, titanium, and alloys thereof. The metal housing can be formed from a foil having a thickness of about 5-100 μm or about 10-250 μm. In some embodiments, the foil can be up to about 1 mm thick. Whether the housing is flexible or rigid depends on the choice of material, thickness, and any treatments that have been applied to the metal, such as heat treatment or hot or cold working.

[0135] In some embodiments, the housing for the adsorbent material sheet can be omitted entirely, with the adsorbent material sheet contained within the fuel tank itself. In such a configuration, the adsorbent material sheet can be attached to a portion of the interior of the fuel tank that is not regularly in contact with the liquid fuel and freely adsorbs fuel vapors. This portion is typically the top or side of the fuel tank, or a combination thereof. The fuel tank may also include a recessed portion on the top or side that is designed to contain the adsorbent material sheet and allow the adsorbent material sheet to adsorb fuel vapors. Such an embodiment in which the adsorbent material sheet is attached to the interior portion of the fuel tank not only provides maximum space savings and weight reduction by omitting the canister structure, but also simplifies manufacturing and installation because the sheet is already installed within the fuel tank during vehicle assembly.

[0136] The shell can also be eliminated by forming a coiled or folded adsorbent sheet and then selectively curing the outer sheet so that the outer sheet forms a durable cured shell that acts as a support for the inner coiled or folded adsorbent sheet. Such selective curing can be accomplished thermally or with a chemical bath, or by actinic radiation such as ultraviolet light, or by electron beam curing.

[0137] In embodiments where the sheet of adsorbent material omits the housing and is contained within the vehicle fuel tank itself, the sheet of adsorbent material can be attached to the fuel tank in a variety of ways. The sheet of adsorbent material can be fastened using mechanical fasteners (e.g., screws, rivets, or clamps), or the sheet of adsorbent material can be fastened using an adhesive backing positioned between the fuel tank wall and the sheet of adsorbent material. The adhesive backing can be a single layer of adhesive or a double-sided tape or sheet. The adhesives used in the adhesive backing can include pressure sensitive adhesives, UV curable adhesives, thermal curable adhesives, hot melt adhesives, and reactive multi-component adhesives. Adhesive compositions include acrylic and (meth) acrylic acids, acrylates and (meth) acrylates, epoxies in one- and two-component formulations, and urethanes.

[0138] The adsorbent sheet can be applied in a variety of ways during the manufacturing process. In some embodiments, the fuel tank can be formed and the adsorbent sheet applied in a separate step, wherein the adhesive is applied and then the adsorbent sheet is applied. In other embodiments, the adsorbent sheet is placed inside a mold, with or without an adhesive backing, as appropriate, and the fuel tank is injection- or blow-molded around the adsorbent sheet. In other embodiments, the adsorbent sheet can be co-extruded with sheets of material forming the sides of the fuel tank, and the edges of those sheets adhered or welded together to seal the final tank internally with the adsorbent sheet.

[0139] When the adsorbent sheet is contained within a vehicle fuel tank without a housing, the fuel tank can include additional valves and ports to accommodate the adsorption and desorption of fuel vapors within the tank. For example, during engine operation, air can be introduced into the fuel tank to desorb the fuel vapors contained within the adsorbent sheet, as well as those present within the tank. These desorbed fuel vapors are then delivered to the engine for combustion during optimal cycling (as directed by the ECU).

[0140] When the adsorbent material sheets are provided without a housing and are contained within a tank (e.g., a vehicle fuel tank), the adsorbent material sheets can be positioned so that they are occasionally immersed in the volatile liquid typically contained within the tank. This ensures that the adsorbent material sheets do not become saturated prematurely and also ensures that sufficient surface area is exposed to the vapor within the fuel tank to achieve adsorption of the vapor. The features contemplate that the adsorbent material sheets can be placed in an unfilled portion of the tank (e.g., the air gap or headspace of the tank), or near a baffle that prevents liquid from splashing onto the adsorbent material sheets. The adsorbent material sheets can also be placed in a dedicated portion of the tank that liquid cannot enter, such as a small chamber or niche.

[0141] The device of different embodiments may include the above-mentioned shell and adsorbent material sheets. The shell can be of any shape and can be configured to purify gas or liquid. For example, in some embodiments, the shell can be of any shape, such as cube-like, cubic or cylindrical. The adsorbent material sheet can be manufactured to a certain size to fit within the shell and substantially fill the space within the shell through which the gas or liquid passes. In some embodiments, two or more adsorbent material sheets can be stacked to substantially fill the shell, and in other embodiments, the adsorbent material sheets can be wound to form a spirally wound sheet or pressed to form a stacked sheet. In some embodiments, the stacked or pressed sheets can be such that the sides of adjacent sheets are substantially adjacent. In other embodiments, the stacked or pressed sheets can be positioned so that adjacent sheets are spaced apart. For example, in certain embodiments, the sheet can be corrugated, having adsorbent material sheets that form series or parallel ridges and grooves, and in some embodiments, the corrugated adsorbent material sheets can be separated by flat adsorbent material sheets. The corrugated adsorbent material sheets can be arranged in a stacked or wound / spirally wound form within the shell.

[0142] In various embodiments, the void fraction can be about 30% to about 32% less than the void volume of current devices, and in some embodiments, the void fraction can be less than 10%. For example, the device can have a void fraction of about 45% to about 2%, about 35% to about 5%, about 25% to about 7%, or any individual void fraction or range encompassed by these example ranges. Devices of various embodiments can exhibit less flow restriction, such as pressure drop, than devices having granular or pelletized adsorbent material. Consequently, more adsorbent material can be incorporated into such a device without reducing the flow rate of the device.

[0143] The devices of such embodiments can have a butane working capacity ("BWC") greater than about 5.0 g / 100 cc, and in some embodiments, the devices can have a BWC of about 4.0 g / 100 cc to about 20 g / 100 cc, 5.0 g / 100 cc to about 18 g / 100 cc, about 7.0 g / 100 cc to about 16 g / 100 cc, or about 8.0 g / 100 cc to about 15 g / 100 cc, or any individual BWC or range encompassed by these embodiments. The devices can exhibit pressure drops that are more than equivalent to a densely packed bed of conventional activated carbon or other activated compound powders, pellets, or granules. This feature is advantageous because it ensures that the adsorbent material sheet product of the present invention (whether stacked, coiled, wound, or otherwise configured) has the same ability to handle and transfer vapors and gases as conventional devices, despite the increased adsorbent performance.

[0144] When the stacked or coiled adsorbent material product is combined with a housing, it can be used as a vapor loss canister or other device. As described above, the shape and characteristics achieved by the stacked or coiled product allow for unique placement and improved performance.

[0145] According to some embodiments, a vapor loss canister includes a housing having at least one sidewall defining an interior space, and an adsorbent sheet product, wherein the adsorbent sheet media is sized and configured to fit within the housing and substantially fill the entire interior space within the housing, wherein the interior space is substantially free of additional internal material other than the adsorbent sheet media. In other words, conventional vapor loss canisters require springs, filters, support substrates, etc. to hold and maintain loose carbon powder or pellets. Because the adsorbent sheet is substantially self-supporting, these additional support structures are not required. This allows for the inclusion of more material or the use of a smaller canister without sacrificing performance.

[0146] In some embodiments, the sorbent sheet product comprises stacked sorbent sheet media, including those described above. In such cases, the housing or canister can take any shape as discussed above, but in some embodiments, the housing or canister is relatively flat and flexible for containing the stacked sorbent sheet media, which has a height significantly less than its length or width. In these cases, the housing can be a flexible bag or pouch, as discussed above.

[0147] In some cases, the canister is adapted to be placed on top of the fuel tank or even within the fuel tank.

[0148] In some embodiments, the sorbent sheet product comprises a rolled sorbent sheet product as described above.In some cases, at least a portion of the housing sidewall defines a filter that does not substantially occupy any internal canister space.

[0149] In some embodiments, a fuel tank may be provided with an integrated vapor adsorption system. Such a tank comprises a tank structure, at least one stacked or rolled adsorbent sheet material product, and at least one fastening device that secures the adsorbent material product to a surface of the tank that is occasionally immersed in a volatile liquid contained within the tank. The fastening device may be an adhesive layer formed between one surface of the adsorbent material product and a tank wall.

[0150] Such adhesives can be at least one of pressure sensitive adhesives, UV curing adhesives, heat curing adhesives, hot melt adhesives, reactive multi-component adhesives, acrylic and (meth)acrylic adhesives, acrylate and (meth)acrylate adhesives, epoxy adhesives in one-component and two-component formulations, urethane adhesives, and copolymers and combinations thereof.

[0151] The tank may further include one or more of at least one fuel pump, a fuel delivery line, a fuel return line, an atmospheric vent line, a port, a valve, a sensor, an air inlet, an open cell foam, a baffle, a bladder, and combinations thereof.

[0152] In some embodiments, the tank is a fuel tank having a "ship in a bottle" configuration.

[0153] Some embodiments provide a vehicle-mounted refueling vapor recovery device comprising an adsorbent material sheet product as described herein. The vehicle-mounted refueling vapor recovery device may include a vapor adsorption canister as described herein. The vehicle-mounted refueling vapor recovery device may include a tank with integrated vapor adsorption as described in Example 22 of the Summary of the Invention.

[0154] Additional parts

[0155] The present invention may include sensors, such as fuel composition sensors. The fuel composition sensor may be used to detect the mixture of gasoline and ethanol contained within the housing and adsorbent material, and this information may be transmitted to the ECU so that the vapors released later to the engine can be used more accurately during engine combustion. Other sensors include temperature sensors, vapor pressure sensors, oxygen sensors, etc. Depending on the type of information required by the ECU, the sensors may operate on the principles of electrochemical interactions, electronics such as thermocouples, electromechanical, refractive index, infrared spectroscopy, etc. The sensors may be included within the housing alone or in combination, or, if no housing is specified, within the area containing the sheet of adsorbent material. The sensors may be included in holes or notches cut from the sheet, or in the space between the sheets, where the sheet is wrapped or folded around the sensor.

[0156] The present invention may include inlets, outlets, hoses, and associated valves to control the flow of fuel vapor into and out of the adsorbent material of the present invention. The openings may be static, or they may have valves that open and close as required by the ECU to control the flow of vapor into and out of the adsorbent sheet of the present invention. For example, during refueling, the outlet valve remains closed to ensure that the displaced fuel vapor does not escape into the atmosphere. However, when the engine is running and the ECU requires it, at least one outlet valve can be opened to allow the adsorbed vapor to be released into the engine to allow it to burn. If there is too much fuel vapor for the adsorbent material sheet of the present invention to safely adsorb, a vent and valve to the atmosphere may also be included. An inlet and valve for air or other gas (e.g., inert exhaust gas) may also be included to desorb the fuel vapor as it is sent to the engine for combustion.

[0157] The present invention also contemplates the inclusion and integration of other components that make up the ORVR system and apparatus. These other components may include an active compressor and condenser, a fuel tank heater, a fuel tank heat exchange coil for cooling the enclosed fuel, a fuel filler neck, a fuel filler neck (including a capless fuel filler neck), a vent for fuel vapors, a fuel line for delivering fuel, a fuel return line, a vent and vehicle rollover valve, a fuel pump, and an air inlet valve or air purge valve.

[0158] The present invention also contemplates devices and structures that can be combined with sheets of adsorbent material to improve or control the adsorption and desorption of fluids and gases. For example, a fan or pump can be included to force fluid or vapor onto the sheet of adsorbent material (as it is assembled), thereby allowing the sheet of adsorbent material to be packed or wound more tightly or allowing for a larger device than would otherwise be possible with the same amount of fluid spread across the sheet. Alternatively, the device can include a resistive element heater or a Peltier effect heater or cooler designed to heat and / or cool a fluid and thereby force the fluid to move across the sheet of adsorbent material of the claimed invention. For example, heated, expanded fluid can be exhausted upward and drawn into the bottom of a coiled or wound article that is oriented vertically to take advantage of the effects of gravity.

[0159] Other Uses

[0160] In addition to automotive uses, the inventors also contemplate that the adsorbent sheets of the claimed invention may be used in any situation where a tank or other enclosed space is designed to hold volatile liquids, particularly volatile hydrocarbons such as fuels, solvents, and other volatile compounds. Examples include, but are not limited to, fuel tanks in aircraft, fuel tanks in ships and other marine vehicles, fuel tanks in trucks, chemical tanks in railcars, barges, ships, trucks, vehicles, and other bulk carriers, and stationary chemical tanks. The adsorbent material sheets of the claimed invention may also be attached or adhered to the walls of confined spaces where the presence of volatile compounds would be harmful, for example, in chemical facilities where operators and maintenance personnel must regularly enter the space. When used in such combined spaces, such adsorbent material sheets may not only increase the safety of operators and maintenance personnel, but they may also reduce the need for bulky protective equipment.

[0161] In some embodiments, the device may not filter microscopic particles and, therefore, would have utility outside the fuel vapor recovery arena. Devices containing granular or pelletized adsorbent material filter particles larger than about 1% of their diameter, thereby removing these particles from the gas or liquid being processed using the device. Because devices containing stacked or coiled / spirally wound sheets of adsorbent material allow such particles to pass through without filtering, devices of various embodiments can be used to filter biological fluids, such as blood, where red and white blood cells and platelets, etc., must pass through the filter without being physically filtered out of the blood. Other contaminants can be adsorbed onto the sheets of adsorbent material and removed from the blood filtrate.

[0162] Examples

[0163] Although the present invention has been described in considerable detail with reference to certain preferred embodiments thereof, other versions are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description and preferred variations contained in this specification. Various aspects of the present invention will be illustrated with reference to the following non-limiting examples.

[0164] As discussed above, BWC is a measure of the performance of activated carbon. The BWC of a sample is determined by measuring the ability of the activated carbon to adsorb and desorb butane from dry air under specific conditions and measuring the difference between the butane adsorbed at saturation and the butane retained per unit volume of carbon after a specified purge. BWC can be tested in several ways, including procedures specified by the American Society for Testing and Materials International (ASTM International) and known to those skilled in the art. Specifically, the test can follow ASTM D5228, including revisions D5228-16, D5228-92 (2015), D5228-92 (2005), and D5228-16. - 92(2000).

[0165] In Examples 1-4, the carbon sheets were spirally wound to produce a 10% void fraction, which gave about a 30% performance improvement compared to activated carbon ("PAC") alone. Similar to Comparative Example 1, the void fraction of the comparative granular or powdered bed of activated carbon was about 40% void fraction by volume. The Examples and Comparative Examples are described below.

[0166] Example 1

[0167] Activated carbon membranes were made from CPL (CT#14299-8), which is a wood-based activated carbon activated using phosphoric acid. Membranes were also made from CPW (CT#14299-10), which is a wood-based activated carbon activated using phosphoric acid. The activated carbon was crushed in a mechanical mortar and pestle and mixed with 9% PTFE powder. The resulting composition had a bread dough-like consistency. The composition was rolled to form sheets having a thickness of 0.448 mm (CT#14299-8 1), 0.411 mm (CT#14299-8 2), 0.459 mm (CT#14299 - 10 1), and 0.439 mm (CT#14299-10 2) sheets.

[0168] Example 2

[0169] Activated carbon sheets were prepared as described in Example 1 using BVC-11 8x25 activated carbon (a nut shell based activated carbon activated with phosphoric acid). This formed sample CT#14266-1. Samples were also formed using BVC-11 8x35 (also a nut shell based activated carbon activated with phosphoric acid). This formed sample CT#14266-2. The sheets formed had thicknesses of 0.330 mm (CT#14266-11), 0.334 mm (CT#14266-12), 0.327 mm (CT#14266-13), 0.317 mm (CT#14266-21), 0.307 mm (CT#14266-14266-15), 0.317 mm (CT#14266-16), 0.317 mm (CT#14266-17), 0.317 mm (CT#14266-18), 0.317 mm (CT#14266-19), 0.317 mm (CT#14266-21), 0.317 mm (CT#14266-22), 0.317 mm (CT#14266-23), 0.317 mm (CT#14266-24), 0.317 mm (CT#14266-25), 0.317 mm (CT#14266-27), 0.317 mm (CT#14266-28), 0.317 mm (CT#14266-29), 0.317 mm (CT#14266-21), 0.317 mm (CT#14266-21), 0.317 mm (CT#14266-29), 0.317 mm (CT#14266-21), - 2 2), and 0.328 mm (CT#14266-2 3).

[0170] Butane Operation Tests - Examples 1 and 2

[0171] The activated carbon sheets prepared in Examples 1 and 2 were tested for butane adsorption using the butane working test. In this test, the sheets were rolled and placed in a tube. Butane was added to the tube and butane adsorption was measured. A Tactic experiment, used to predict BWC performance, was run on small stacks of five slat sheets. The results are shown in Tables 1 and 2:

[0172] Table 1 (Example 2)

[0173]

[0174] Table 2 (Example 1)

[0175]

[0176]

[0177] Example 3

[0178] Activated carbon sheets were prepared as in Examples 1 and 2, but using granular activated carbon #3445-32-4. The activated carbon sheets were also not tightly rolled as in the previous Examples 1 and 2, and the resulting sheets were tested for butane adsorption using the Butane Working Capacity Test. In both tests, two separate stacks of 20 0.45 mm thick sheets were cut into rectangles of 2.2 cm x 7.5 cm ± 10% and sealed on the sides with 0.05 mm thick and 2 mm wide double-sided tape. In this configuration, the tape thickness defines the average sheet spacing. The total height of each stack of 20 sheets with tape spacers was 1 cm. These stacks of sheets were then placed in a large 2.54 cm diameter cylindrical glass tube for butane adsorption / desorption testing. The remaining volume between the rectangular sheet stack and the cylindrical glass tube wall was filled with closed-cell expanding foam to occupy the remaining volume and sealed to prevent bypass gas flow through the inserted test sample. Butane or air was forced to flow through the 0.05 mm gaps between the 20 sheets. The flow rate and the volume of the sheet stack were selected to maintain the ASTM working capacity procedure. The ASTM procedure was followed, except that a sheet stack was used instead of a particle bed, closed-cell expansion foam was used for sealing, and a larger cylindrical glass tube arrangement was required to accommodate the rectangular sheet stack.

[0179] During a modified ASTM procedure, butane or air was forced to flow in the 0.05 mm gaps between the 20 sheets, with the flow rate and volume of the sheet stack maintained within the ASTM specifications for working capacity. The results of Example 3 are in Table 3 below.

[0180] Comparative Example 1

[0181] A comparative example was also prepared using the same granular activated carbon #3445-32-4 as in Example 4, but without forming the granular activated carbon into a sheet or roll. The granular activated carbon was tested according to ASTM procedures. The results of this testing are in Table 3 below.

[0182] Table 3 (Example 3 and Comparative Example 1)

[0183]

[0184]

[0185] Conclusions and Summary of Examples 1-3 and Comparative Example 1

[0186] The relevant data are summarized in Table 4 below:

[0187] Table 4: Data summary

[0188]

Claims

1. A steam adsorption tank comprising an adsorbent material sheet product, comprising at least two sheets of adsorbent material, wherein each sheet of adsorbent material has a defined upper surface and a lower surface, the upper and lower surfaces having a combined total surface area, and wherein each adsorbent material sheet comprises an adsorbent material and a binder, and The adhesive comprises at least polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, heat-curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof, wherein each sheet of adsorbent material is stacked and arranged such that adjacent upper and lower surfaces of the individual sheets are parallel and aligned to allow fluid to flow at least between said adjacent upper and lower surfaces, wherein the adsorbent material sheet product has a void volume of 2% to 25%, and A shell at least partially encapsulates the sheet product of adsorbent material.

2. The vapor adsorption tank according to claim 1, wherein: The adsorbent material sheet product has a BWC stacking multiplier ratio of 1.1 to 1.3, wherein the BWC stacking multiplier ratio is defined by the following formula: BWC stacking multiplier ratio = [(measured BWC of the entire adsorbent material sheet product) / (measured BWC of an individual adsorbent material sheet outside the product)] / number of adsorbent material sheets in the adsorbent material sheet product.

3. The vapor adsorption tank according to claim 1, wherein: An independently measured piece of the adsorbent material has a BWC value that is 5% to 15% higher than the BWC of the same weight of adsorbent material in pelletized or powdered form.

4. The vapor adsorption tank according to claim 1, wherein: At least one of the sheets of adsorbent material is configured to be flat, spirally cylindrically wound, elliptical wound, elongated rectangular rod wound, folded, "S" shaped laminated, formed into concentric cylinders, formed into concentric ellipses, formed into concentric rectangular rods, or a combination of these forms.

5. The vapor adsorption tank according to claim 1, wherein: At least one of the sheets of adsorbent material has raised and / or recessed portions.

6. The vapor adsorption tank according to claim 5, wherein: The raised and / or recessed portions are present on adjacent sheets and are embedded.

7. The vapor adsorption tank according to claim 5, wherein: The raised and / or recessed portions are present on adjacent sheets and are not embedded.

8. The vapor adsorption tank according to claim 1, wherein: Each individual piece of adsorbent material has a density of 0.08 g / cc to 1.5 g / cc.

9. The vapor adsorption tank according to claim 1, wherein: The adsorbent material sheet product has a BWC greater than 10 g / 100 cc.

10. The vapor adsorption tank according to claim 1, wherein: The adsorbent material sheet product has a BWC of 7.0 g / 100 cc to 30 g / 100 cc.

11. The vapor adsorption tank according to claim 1, wherein: The adsorbent material sheet comprises adsorbent material particles having at least two populations with different average particle sizes, and wherein the average particle sizes of the two populations have a ratio of 1:2 to 1:

10.

12. The vapor adsorption tank according to claim 1, wherein: The amount of binder and the amount of adsorbent material sheet product are present in a gradient such that the amount of binder is highest on the exterior of the adsorbent material sheet product and the amount of binder is lowest on the interior of the adsorbent material sheet product.

13. The vapor adsorption canister according to claim 1, wherein: At least one of the sheets of adsorbent material includes holes, cutouts or openings.

14. The vapor adsorption canister according to claim 1, wherein: The shell includes polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

15. A vapor adsorption canister comprising a wound adsorbent material sheet product, comprising: a sheet of adsorbent material defining an upper surface and a lower surface and having a total surface area, and comprising an adsorbent material and a binder, The adhesive includes polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamide polymers, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof, wherein the sheets of adsorbent material are spirally wound to form adjacent sheets that allow fluid to flow around and between adjacent sheets, wherein the adsorbent material sheet product has a void volume of 2% to 25%, and A shell at least partially encloses the rolled sheet of adsorbent material product.

16. The vapor adsorption canister according to claim 15, wherein: The sheet of adsorbent material in its coiled form has a BWC that is at least 10% higher than the BWC of the same sheet of adsorbent material in its unrolled form.

17. The vapor adsorption canister according to claim 15, wherein: The wound adsorbent material sheet product has a BWC that is at least 10% higher than the BWC of a pelletized or powdered form of the same amount of adsorbent material in the adsorbent sheet.

18. The vapor adsorption canister according to claim 15, wherein: The rolled adsorbent material sheet product has a generally cylindrical shape having a length greater than its diameter.

19. The vapor adsorption canister of claim 15, wherein: The wound adsorbent material sheet product is wound to 500-700 kg / m 3 The average volume density.

20. The vapor adsorption canister of claim 15, wherein: The wound adsorbent material sheet product has a butane working capacity greater than 10 g / 100 cc.

21. The vapor adsorption canister of claim 15, wherein: The wound adsorbent material sheet product has a butane working capacity of 7.0 g / 100 cc to 30 g / 100 cc.

22. The vapor adsorption canister of claim 15, wherein: The wound sheet of adsorbent material comprises at least two populations of adsorbent material particles, wherein each of the at least two populations has a different average particle size.

23. The vapor adsorption canister of claim 15, wherein: The wound adsorbent material sheet comprises adsorbent material particles having at least two populations with different average particle sizes, and wherein the average particle sizes of the two populations have a ratio of 1:2 to 1:

10.

24. The vapor adsorption canister of claim 15, wherein: The housing is flexible.

25. The vapor adsorption canister of claim 15, wherein: The shell includes one or more of polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermally curable divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aromatic polyamide polymers, para-aromatic polyamides, meta-aromatic polyamide polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimides, polyamide-imides, polyurethanes, low-density and high-density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, and copolymers and combinations thereof.

26. The vapor adsorption canister of claim 15, wherein: The shape of the housing conforms to the shape of the closed, coiled sheet of adsorbent material product.

27. The vapor adsorption canister of claim 15, further comprising: At least one structure selected from the group consisting of a tube, an inlet, an outlet, a sensor, a valve, and a fluid channel.

28. An on-vehicle refueling vapor recovery device comprising the vapor adsorption canister according to claim 1.

29. An on-vehicle refueling vapor recovery device comprising the vapor adsorption canister of claim 15.

Images