Canister manufacturing method

Abstract

To provide a technology for reducing pressure loss in a canister.SOLUTION: A canister has an activated carbon molding that adsorbs evaporated fuel generated in a fuel tank of a vehicle, and an adsorption chamber that houses the activated carbon molding. A method for manufacturing a canister comprises pressing or suctioning fibrous activated carbon in a predetermined direction to form a columnar activated carbon molding, and arranging the activated carbon molding in the adsorption chamber so that a pressing or suctioning direction of the activated carbon molding is perpendicular to a flow direction of the evaporated fuel.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a canister. [Background technology]

[0002] Patent Document 1 describes a canister having activated carbon molded bodies and an adsorption chamber. The activated carbon molded bodies are accommodated in the adsorption chamber. The activated carbon molded bodies adsorb evaporated fuel generated in a vehicle fuel tank. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2023 / 054088 Summary of the Invention [Problem to be solved by the invention]

[0004] As described in Patent Document 1, it is preferable that the pressure loss in the canister is small. One aspect of the present disclosure provides a technique for reducing the pressure loss in the canister. [Means for solving the problem]

[0005] One aspect of the present disclosure is a method for manufacturing a canister having activated carbon molded bodies for adsorbing evaporated fuel generated in a vehicle fuel tank and an adsorption chamber for housing the activated carbon molded bodies. The method includes pressing or sucking activated carbon fibers in a predetermined direction to form cylindrical activated carbon molded bodies, and placing the formed activated carbon molded bodies in the adsorption chamber so that the pressing or sucking direction of the activated carbon molded bodies is perpendicular to the flow direction of evaporated fuel. This configuration reduces pressure loss in the canister.

[0006] In one aspect of the present disclosure, a dispersion liquid in which the fibrous activated carbon is dispersed may be poured into a mold having a bottom wall formed with a plurality of through-holes, and the dispersion liquid may be sucked toward the bottom wall to form an activated carbon molded body. With this configuration, a canister with reduced pressure loss can be realized using a relatively simple device.

[0007] In one aspect of the present disclosure, the activated carbon molded bodies disposed in the adsorption chamber may have an equivalent diameter in a cross section perpendicular to the direction of the vaporized fuel flow that is larger than the length along the direction of the vaporized fuel flow. This configuration makes it possible to realize a canister having activated carbon molded bodies whose equivalent diameter in a cross section perpendicular to the direction of the vaporized fuel flow is larger than the length along the direction of the vaporized fuel flow, and which has reduced pressure loss.

[0008] In one aspect of the present disclosure, an outer peripheral surface of the activated carbon molded body disposed in the adsorption chamber, around the direction of flow of the evaporated fuel, may be in contact with an inner surface of the adsorption chamber.

[0009] In one aspect of the present disclosure, the adsorption chamber may be connected to an atmospheric port that is open to the atmosphere. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 2 is a cross-sectional view of the canister according to the first embodiment. [Figure 2] Fig. 2A is a schematic diagram showing a molding step according to the first embodiment, Fig. 2B is a schematic diagram showing the state subsequent to Fig. 2A in the molding step according to the first embodiment, and Fig. 2C is a schematic diagram showing the third adsorbent formed in the molding step according to the first embodiment. [Figure 3] 4A to 4C are cross-sectional views showing an arrangement step according to the first embodiment. [Figure 4] Fig. 4A is a schematic diagram showing a molding step according to the second embodiment, Fig. 4B is a schematic diagram showing the state subsequent to Fig. 4A in the molding step according to the second embodiment, and Fig. 4C is a schematic diagram showing the third adsorbent formed in the molding step according to the second embodiment. [Figure 5]Fig. 5A is a schematic diagram showing the molding process in the molding step according to the third embodiment, Fig. 5B is a schematic diagram showing the cutting process in the molding step according to the third embodiment, and Fig. 5C is a schematic diagram showing the third adsorbent formed in the molding step according to the third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings.

[0012] [1. First embodiment] [1-1. Canister configuration] 1 is an evaporated fuel treatment device that adsorbs and desorbs evaporated fuel generated in a vehicle fuel tank. The canister 1 includes a charge port 2A, a purge port 2B, an atmospheric port 2C, a case 3, a first adsorbent 4A, a second adsorbent 4B, a third adsorbent 4C, a first filter 5A, a second filter 5B, a third filter 5C, a fourth filter 5D, a fifth filter 5E, a first grid 6A, a second grid 6B, a first spring 7A, and a second spring 7B.

[0013] The charge port 2A is connected to a fuel tank of the vehicle via a pipe and is configured to take in evaporated fuel generated in the fuel tank into the canister 1.

[0014] The purge port 2B is connected to an intake pipe of a vehicle engine via a purge valve, and is configured to discharge evaporated fuel from the canister 1 and supply it to the engine.

[0015] The atmospheric port 2C is open to the atmosphere via a pipe. The atmospheric port 2C is configured to release gas from which evaporated fuel has been removed into the atmosphere. The atmospheric port 2C is configured to take in external air (i.e., purge air) to desorb (i.e., purge) the evaporated fuel adsorbed by the canister 1.

[0016] The case 3 is a housing that forms a space inside. The case 3 is provided with a charge port 2A, a purge port 2B, and an atmospheric port 2C. The case 3 has a first adsorption chamber 31, a second adsorption chamber 32, a third adsorption chamber 33, and a communication portion 34.

[0017] The first adsorption chamber 31 is a portion that accommodates the first adsorbent 4A. The first adsorption chamber 31 is cylindrical and has a bottom. Hereinafter, the end of the first adsorption chamber 31 that is closest to the bottom wall 311 in the axial direction will be referred to as the first end 31a of the first adsorption chamber 31. The end of the first adsorption chamber 31 opposite the first end 31a in the axial direction will be referred to as the second end 31b of the first adsorption chamber 31. The bottom wall 311 is provided with a charge port 2A and a purge port 2B. That is, the charge port 2A and the purge port 2B are connected to the first adsorption chamber 31. More specifically, the fact that the charge port 2A and the purge port 2B are connected to the first adsorption chamber 31 means that the charge port 2A and the purge port 2B are connected to the first adsorption chamber 31 directly (i.e., without going through another chamber).

[0018] The first adsorption chamber 31 communicates with the second adsorption chamber 32 at the second end 31b via a communication portion 34. The flow direction of the evaporated fuel in the first adsorption chamber 31 is parallel to the axial direction of the first adsorption chamber 31. Arranged inside the first adsorption chamber 31 are a first adsorbent 4A, a first filter 5A, a second filter 5B, and a first grid 6A.

[0019] The first adsorbent 4A adsorbs evaporated fuel generated in the fuel tank of the vehicle. The first adsorbent 4A in this embodiment is an aggregate of granular activated carbon.

[0020] The first filter 5A and the second filter 5B are configured to block the first adsorbent 4A but allow gas to pass through. In the first adsorption chamber 31, the first filter 5A and the second filter 5B are arranged on either side of the first adsorbent 4A in the flow direction of the evaporated fuel. The first filter 5A is adjacent to the first adsorbent 4A on the side of the first end 31a of the first adsorption chamber 31. The second filter 5B is adjacent to the first adsorbent 4A on the side of the second end 31b of the first adsorption chamber 31.

[0021] The first grid 6A is a plate-like member having ventilation holes formed therein. The first grid 6A has, for example, a lattice shape. The first grid 6A is adjacent to the second filter 5B on the side of the second end 31b of the first adsorption chamber 31 (i.e., the side opposite to the first adsorbent 4A).

[0022] In the first adsorption chamber 31, the first adsorbent 4A is pressed toward the charge port 2A and purge port 2B by a first spring 7A via a second filter 5B and a first grid 6A. The first spring 7A is an elastic member that biases an object in a predetermined direction.

[0023] The second adsorption chamber 32 is a portion that accommodates the second adsorbent 4B. The second adsorption chamber 32 is cylindrical. Hereinafter, both axial ends of the second adsorption chamber 32 will be referred to as the first end 32a and the second end 32b of the second adsorption chamber 32. The second adsorption chamber 32 is arranged radially alongside the first adsorption chamber 31. The second adsorption chamber 32 is arranged such that the first adsorption chamber 31 and the second ends 31b, 32b face the same side.

[0024] The second adsorption chamber 32 communicates with the first adsorption chamber 31 at a second end 32b via a communication portion 34. The second adsorption chamber 32 communicates with the third adsorption chamber 33 at a first end 32a. The direction of the flow of evaporated fuel in the second adsorption chamber 32 is parallel to the axial direction of the second adsorption chamber 32. A second adsorbent 4B, a third filter 5C, a fourth filter 5D, and a second grid 6B are arranged inside the second adsorption chamber 32.

[0025] The second adsorbent 4B adsorbs the evaporated fuel generated in the fuel tank of the vehicle. In this embodiment, the second adsorbent 4B is an aggregate of granular activated carbon.

[0026] The third filter 5C and the fourth filter 5D are configured to block the second adsorbent 4B but allow gas to pass through. In the second adsorption chamber 32, the third filter 5C and the fourth filter 5D are arranged on either side of the second adsorbent 4B in the flow direction of the evaporated fuel. The third filter 5C is adjacent to the second adsorbent 4B on the side of the first end 32a of the second adsorption chamber 32. The fourth filter 5D is adjacent to the second adsorbent 4B on the side of the second end 32b of the second adsorption chamber 32.

[0027] The second grid 6B is a plate-like member having ventilation holes formed therein. The second grid 6B has, for example, a lattice shape. The second grid 6B is adjacent to the fourth filter 5D on the second end 32b side of the second adsorption chamber 32 (i.e., the side opposite to the second adsorbent 4B side).

[0028] In the second adsorption chamber 32, the second adsorbent 4B is pressed toward the third adsorption chamber 33 (i.e., toward the atmospheric port 2C, as described below) by the second spring 7B via the fourth filter 5D and the second grid 6B. The second spring 7B is an elastic member that biases an object in a predetermined direction.

[0029] The third adsorption chamber 33 is a portion that accommodates the third adsorbent 4C. The third adsorption chamber 33 has a tubular portion 331 and a lid portion 332. The tubular portion 331 is a tubular portion. In this embodiment, the tubular portion 331 has a rectangular tubular shape. Hereinafter, both axial ends of the tubular portion 331 are referred to as a first end 331a and a second end 331b of the tubular portion 331. The lid portion 332 is disposed so as to cover the opening of the first end 331a of the tubular portion 331. The lid portion 332 is joined to the tubular portion 331 by, for example, vibration welding. The lid portion 332 is provided with an atmospheric port 2C. That is, the atmospheric port 2C is connected to the third adsorption chamber 33. The connection of the atmospheric port 2C to the third adsorption chamber 33 means, more specifically, that the atmospheric port 2C is connected to the third adsorption chamber 33 directly (i.e., without going through another chamber).

[0030] The third adsorption chamber 33 is arranged radially next to the first adsorption chamber 31. The third adsorption chamber 33 is arranged so that the first end 331a of the tubular portion 331 faces the same side as the first end 31a of the first adsorption chamber 31. The third adsorption chamber 33 is also arranged axially next to the second adsorption chamber 32. The axial direction of the third adsorption chamber 33 coincides with the axial direction of the tubular portion 331.

[0031] The third adsorption chamber 33 communicates with the second adsorption chamber 32 at the second end 331b of the cylindrical portion 331. The flow direction of the evaporated fuel in the third adsorption chamber 33 is parallel to the axial direction of the third adsorption chamber 33. A third adsorbent 4C and a fifth filter 5E are disposed inside the third adsorption chamber 33.

[0032] The third adsorbent 4C adsorbs evaporated fuel generated in the vehicle fuel tank. The third adsorbent 4C is an activated carbon molding formed from fibrous activated carbon. The third adsorbent 4C is integrally molded. In other words, the third adsorbent 4C is not a combination of multiple activated carbon moldings, but a single activated carbon molding.

[0033] The third adsorbent 4C is columnar. In this embodiment, the third adsorbent 4C is square columnar. The third adsorbent 4C is disposed in the third adsorption chamber 33 such that its axial direction coincides with the axial direction of the third adsorption chamber 33. The outer peripheral surface of the third adsorbent 4C is in contact with the inner surface of the third adsorption chamber 33. The outer peripheral surface of the third adsorbent 4C refers to the outer surface of the third adsorbent 4C around the axial direction of the third adsorbent 4C. In other words, the outer peripheral surface of the third adsorbent 4C refers to the outer surface of the third adsorbent 4C around the flow direction of the evaporated fuel. The flow direction of the evaporated fuel referred to here is, more specifically, the flow direction of the evaporated fuel in the third adsorption chamber 33.

[0034] The third adsorbent 4C has an equivalent diameter D in a cross section perpendicular to the direction of the vaporized fuel flow that is larger than the length L along the direction of the vaporized fuel flow. The equivalent diameter in a cross section perpendicular to the direction of the vaporized fuel flow is the diameter (D=(S / π)) of the same area S as the cross section perpendicular to the direction of the vaporized fuel flow. 1 / 2 ×2) in the direction of fuel vapor flow.

[0035] The fifth filter 5E is configured to allow gas to pass through while blocking the third adsorbent 4C. The fifth filter 5E is adjacent to the first end 331a side of the tubular portion 331 with respect to the third adsorbent 4C.

[0036] The communication section 34 is a section that forms a communication passage 341 that connects the first adsorption chamber 31 and the second adsorption chamber 32. The communication section 34 is disposed so as to cover the opening of the second end 31b of the first adsorption chamber 31 and the opening of the second end 32b of the second adsorption chamber 32.

[0037] In the canister 1, a substantially U-shaped flow path for evaporated fuel is formed by the first adsorption chamber 31, the communication portion 34, the second adsorption chamber 32, and the third adsorption chamber 33. Evaporated fuel taken in from the charge port 2A is adsorbed by the first adsorption material 4A in the first adsorption chamber 31. Evaporated fuel that cannot be completely adsorbed in the first adsorption chamber 31 flows through the communication passage 341 into the second adsorption chamber 32, where it is adsorbed by the second adsorption material 4B. Furthermore, evaporated fuel that cannot be completely adsorbed in the second adsorption chamber 32 flows into the third adsorption chamber 33, where it is adsorbed by the third adsorption material 4C. The gas from which the evaporated fuel has been removed is released from the atmosphere port 2C.

[0038] Furthermore, by supplying air from the atmospheric port 2C, the evaporated fuel adsorbed in the first adsorption chamber 31, the second adsorption chamber 32, and the third adsorption chamber 33 is discharged from the purge port 2B to the vehicle engine, and as a result, air containing evaporated fuel is supplied to the engine.

[0039] [1-2. Canister manufacturing method] A method for manufacturing the canister 1 will be described with reference to Figures 1 to 3. The method for manufacturing the canister 1 includes at least a molding step and a placement step.

[0040] <Forming process> The molding step is a step of pressing or sucking the activated carbon fibrous 41 in a predetermined direction to mold the third adsorbent 4C. As shown in Figures 2A to 2C, the molding step in this embodiment is a step of sucking the activated carbon fibrous 41 in a predetermined direction to mold the third adsorbent 4C. Hereinafter, the direction in which the activated carbon fibrous 41 is sucked is referred to as the suction direction W1.

[0041] In the molding process of this embodiment, molding apparatus 100 A is used. Molding apparatus 100 A includes molding die 110 and suction unit 120.

[0042] The forming die 110 has a forming surface for forming the fibrous activated carbon 41. The forming die 110 is made of, for example, metal. The forming die 110 forms a recess 111 that corresponds to the outer shape of the third adsorbent 4C. That is, the forming die 110 has a bottom wall 112 that forms the bottom surface of the recess 111, and a side wall 113 that forms the side surface of the recess 111. The bottom surface and side surface of the recess 111 correspond to forming surfaces.

[0043] The bottom wall 112 of this embodiment has a flat plate shape with a rectangular outer shape in a plan view. A plurality of through holes 114 are formed in the bottom wall 112. The bottom wall 112 has, for example, a mesh shape.

[0044] The side wall 113 extends from the entire periphery of the outer periphery of the bottom wall 112 in a plan view to one surface side of the bottom wall 112. The distance S1 between two opposing portions on the inner surface of the side wall 113 (i.e., the side surface of the recess 111) is set corresponding to the length L of the third adsorbent 4C.

[0045] The suction section 120 is configured to suck the inside of the recess 111 through the plurality of through holes 114. In other words, the suction section 120 is configured to suck the inside of the recess 111 toward the bottom wall 112.

[0046] 2A, in the molding step, a dispersion 42 in which fibrous activated carbon 41 is dispersed is placed in a recess 111 of a molding die 110. The dispersion 42 may contain, for example, a binder and granular activated carbon in addition to the fibrous activated carbon 41.

[0047] The dispersion 42 placed in the recess 111 is sucked toward the bottom wall 112 by the suction unit 120, and the moisture is removed. Specifically, as shown in Fig. 2B , the dispersion 42 is sucked toward the bottom wall 112 until the moisture is removed and the height of the fibrous activated carbon 41 from the bottom wall 112 in the recess 111 decreases to a predetermined height H. The predetermined height H is set in accordance with the equivalent diameter D of the third adsorbent 4C.

[0048] In this manner, the dispersion liquid 42 placed in the forming mold 110 is sucked and the water is removed, thereby forming the activated carbon fiber 41 into a columnar shape. In this embodiment, the activated carbon fiber 41 is formed into a rectangular columnar shape. As a result, as shown in FIG. 2C, a third adsorbent 4C is obtained. In the process of sucking the dispersion liquid 42, the activated carbon fiber 41 contained in the dispersion liquid 42 tends to have its fibers oriented perpendicular to the suction direction W1, as shown in FIG. 2B. Therefore, as shown in FIG. 2C, the third adsorbent 4C formed in the molding step tends to contain a large amount of activated carbon fiber 41 oriented perpendicular to the suction direction W1.

[0049] <Placement process> 3 , the disposing step is a step of disposing the third adsorbent 4C formed in the molding step in the third adsorption chamber 33. The third adsorbent 4C formed in the molding step is press-fitted into the tubular portion 331 through the opening at the first end 331a of the tubular portion 331. The third adsorbent 4C is disposed in the tubular portion 331 so that the suction direction W1 in the third adsorbent 4C is perpendicular to the flow direction F of the evaporated fuel. More specifically, the flow direction F of the evaporated fuel in this case refers to the flow direction F of the evaporated fuel in the third adsorption chamber 33.

[0050] Next, the fifth filter 5E is press-fitted into the cylindrical portion 331 through the opening at the first end 331a of the cylindrical portion 331.

[0051] Then, the lid portion 332 is arranged so as to cover the opening of the first end portion 331a of the cylindrical portion 331. The lid portion 332 is joined to the cylindrical portion 331 by, for example, vibration welding.

[0052] As a result of the disposing step, the third adsorbent 4C is disposed in the third adsorption chamber 33 as shown in FIG.

[0053] <Other processes> A first adsorbent 4A, a first filter 5A, a second filter 5B, and a first grid 6A are disposed in the first adsorption chamber 31. A second adsorbent 4B, a third filter 5C, a fourth filter 5D, and a second grid 6B are disposed in the second adsorption chamber 32. A first spring 7A is disposed so as to press the first adsorbent 4A, and a second spring 7B is disposed so as to press the second adsorbent 4B, and a communication portion 34 is disposed in this state. Specifically, the communication portion 34 is disposed so as to cover the opening of the second end 31b of the first adsorption chamber 31 and the opening of the second end 32b of the second adsorption chamber 32.

[0054] Through these steps, the canister 1 is manufactured.

[0055] [1-3.Effects] According to the first embodiment described above in detail, the following effects can be obtained.

[0056] (1a) The method for manufacturing the canister 1 includes a molding step and an arrangement step. In the molding step, the fibrous activated carbon 41 is sucked in a predetermined direction to form the third adsorbent 4C. In the arrangement step, the third adsorbent 4C is arranged in the third adsorption chamber 33 so that the suction direction W1 of the third adsorbent 4C is perpendicular to the flow direction F of the evaporated fuel.

[0057] With this configuration, the molding step can mold the third adsorbent 4C, which contains a large amount of fibrous activated carbon 41 oriented perpendicular to the suction direction W1. Then, in the disposing step, the third adsorbent 4C molded in the molding step is disposed in the third adsorption chamber 33 as described above. This reduces the amount of fibrous activated carbon 41 oriented perpendicular to the flow direction F of the evaporated fuel in the third adsorbent 4C disposed in the third adsorption chamber 33. This reduces the airflow resistance of the third adsorbent 4C. As a result, the pressure loss in the canister 1 can be reduced.

[0058] In the (1b) molding step, a dispersion 42 in which fibrous activated carbon 41 is dispersed is poured into the recess 111 of the forming die 110 and sucked toward the bottom wall 112. This forms the third adsorbent 4C. With this configuration, it is possible to form the third adsorbent 4C, which contains a large amount of fibrous activated carbon 41 oriented perpendicular to the suction direction W1, using a relatively simple device. Therefore, it is possible to realize a canister 1 with reduced pressure loss using a relatively simple device.

[0059] (1c) When forming an adsorbent such as the third adsorbent 4C of this embodiment, in which the length L is smaller than the equivalent diameter D, the fibrous activated carbon is generally sucked in the direction corresponding to the relatively small length L of the adsorbent. When the adsorbent formed in this manner is placed in the adsorption chamber, the suction direction of the adsorbent is parallel to the flow direction of the evaporated fuel in the adsorption chamber. That is, the adsorbent placed in the adsorption chamber tends to contain a large amount of fibrous activated carbon oriented perpendicular to the flow direction of the evaporated fuel. If the adsorbent contains a large amount of fibrous activated carbon oriented perpendicular to the flow direction of the evaporated fuel, the airflow resistance of the adsorbent will be high.

[0060] In contrast, in the manufacturing method of the canister 1 of this embodiment, although the equivalent diameter D of the third adsorbent 4C is larger than the length L, in the molding step, the fibrous activated carbon 41 is sucked in a direction corresponding to the direction of the equivalent diameter D of the third adsorbent 4C to be molded. Then, in the arrangement step, the third adsorbent 4C molded in the molding step is placed in the third adsorption chamber 33 so that the suction direction W1 of the third adsorbent 4C is perpendicular to the flow direction F of the evaporated fuel. With this configuration, it is possible to realize a canister 1 having a third adsorbent 4C whose equivalent diameter D is larger than the length L and which has reduced pressure loss.

[0061] (1d) As described in Patent Document 1, when forming an adsorbent by stacking multiple plate-shaped activated carbon moldings, when placing the adsorbent in an adsorption chamber, it is common to fix the activated carbon moldings together using a fixing device to prevent them from separating.

[0062] In contrast, in this embodiment, the third adsorbent 4C is formed as a columnar activated carbon molding. The third adsorbent 4C is placed in the third adsorption chamber 33 without using any fixing devices. In the completed canister 1, the outer peripheral surface of the third adsorbent 4C around the flow direction of the evaporated fuel is in contact with the inner surface of the third adsorption chamber 33.

[0063] This configuration can reduce the number of steps and parts required when manufacturing the canister 1. This in turn reduces the manufacturing cost of the canister 1.

[0064] [2. Second Embodiment] [2-1. Canister manufacturing method] The method for manufacturing the canister 1 of the second embodiment includes at least a molding step and an arrangement step, similar to the first embodiment. Note that the same reference numerals as those in the first embodiment indicate the same configurations, and reference is made to the preceding description.

[0065] <Forming process> The molding step in the first embodiment is a step of sucking the activated carbon fibrous 41 in a predetermined direction to mold the third adsorbent 4C. In contrast, the molding step in the second embodiment is a step of pressing the activated carbon fibrous 41 in a predetermined direction to mold the third adsorbent 4C, as shown in Figures 4A to 4C. Hereinafter, the direction in which the activated carbon fibrous 41 in the second embodiment is pressed is referred to as the pressing direction W2.

[0066] In the molding step of the second embodiment, a molding apparatus 100B is used. The molding apparatus 100B includes a molding die 130 and a pressing unit 140.

[0067] The forming die 130 is a die having a forming surface for forming the fibrous activated carbon 41. The forming die 130 is made of, for example, metal. The forming die 130 forms a recess 131 that corresponds to the outer shape of the third adsorbent 4C. That is, the forming die 130 has a bottom wall 132 that forms the bottom surface of the recess 131, and a side wall 133 that forms the side surface of the recess 131. The bottom surface and side surface of the recess 131 correspond to forming surfaces.

[0068] The bottom wall 132 of this embodiment has a flat plate shape with a rectangular outer shape in a plan view.

[0069] The side wall 133 extends from the entire periphery of the outer periphery of the bottom wall 132 in a plan view to one surface side of the bottom wall 132. The distance S2 between two opposing portions on the inner surface of the side wall 133 (i.e., the side surface of the recess 131) is set corresponding to the length L of the third adsorbent 4C.

[0070] The pressing portion 140 is configured to be able to slide inside the recessed portion 131. The pressing portion 140 is configured to press inside the recessed portion 131. The pressing surface of the pressing portion 140 corresponds to the molding surface. The pressing surface of the pressing portion 140 refers to the outer surface of the pressing portion 140 that faces the bottom wall 132 when pressing inside the recessed portion 131. The pressing surface in this embodiment is flat.

[0071] In the molding step, as shown in Fig. 4A, the activated carbon fiber 41 is placed in the recess 131 of the mold 130. The activated carbon fiber 41 placed in the recess 131 is pressed toward the bottom wall 132 by the pressing unit 140. Specifically, as shown in Fig. 4B, the activated carbon fiber 41 is pressed toward the bottom wall 132 until the height of the activated carbon fiber 41 from the bottom wall 132 in the recess 131 decreases to a predetermined height H. The predetermined height H is the same as the predetermined height H in the first embodiment.

[0072] By pressing the activated carbon fiber 41 in this manner, the activated carbon fiber 41 is formed into a columnar shape. In this embodiment, the activated carbon fiber 41 is formed into a rectangular columnar shape. As a result, a third adsorbent 4C is obtained, as shown in FIG. 4C. In the process of pressing the activated carbon fiber 41, the fibers of the activated carbon fiber 41 tend to be oriented perpendicular to the pressing direction W2, as shown in FIG. 4B. Therefore, as shown in FIG. 4C, the third adsorbent 4C formed by the molding process tends to contain a large amount of activated carbon fiber 41 oriented perpendicular to the pressing direction W2.

[0073] <Placement process> The arrangement process of the second embodiment is the same as the arrangement process of the first embodiment, except that in the second embodiment, the suction direction W1 in the first embodiment is replaced with the pressing direction W2.

[0074] [2-2. Effects] According to the second embodiment described above in detail, the same effects as those in (1a) and (1b) above can be obtained as described below. Furthermore, the same effects as those in (1c) and (1d) above can also be obtained. Note that the word "suction" in (1c) above should be read as "pressure," and the suction direction W1 should be read as "pressure direction W2."

[0075] (2a) The method for manufacturing the canister 1 of the second embodiment includes a molding step and an arrangement step, similar to the first embodiment. According to this configuration, by pressing the activated carbon fiber 41 in a predetermined direction in the molding step, it is possible to form a third adsorbent 4C containing a large amount of activated carbon fiber 41 oriented perpendicular to the pressing direction W2. Then, in the arrangement step, the third adsorbent 4C is arranged in the third adsorption chamber 33 so that the pressing direction W2 of the third adsorbent 4C is perpendicular to the flow direction F of the evaporated fuel. This reduces the amount of activated carbon fiber 41 oriented perpendicular to the flow direction F of the evaporated fuel in the third adsorbent 4C arranged in the third adsorption chamber 33. Therefore, the same effect as in (1a) above can be obtained.

[0076] In the molding step (2b), the fibrous activated carbon 41 is placed in the recess 131 of the molding die 130 and pressed toward the bottom wall 132. This forms the third adsorbent 4C. This configuration allows a relatively simple device to be used to form the third adsorbent 4C, which contains a large amount of fibrous activated carbon 41 oriented perpendicular to the pressing direction W2. This provides the same effect as in (1b) above.

[0077] 3. Third Embodiment [3-1. Canister manufacturing method] The method for manufacturing the canister 1 of the third embodiment includes at least a molding step and an arrangement step, similar to the first and second embodiments. Note that the same reference numerals as those in the first and second embodiments indicate the same configurations, and reference is made to the preceding explanation.

[0078] <Forming process> 5A to 5C, the molding step of the third embodiment, like the molding step of the second embodiment, is a step of pressing activated carbon fibrous 41 in a predetermined direction to form a third adsorbent 4C. Hereinafter, the direction in which activated carbon fibrous 41 is pressed in the third embodiment is referred to as pressing direction W3. The molding step of the third embodiment includes a molding process and a cutting process.

[0079] (molding process) In the molding process, a molding apparatus 100C shown in Fig. 5A is used. The molding apparatus 100C has a conveyor 150 and rollers 160. The conveyor 150 has a rotatable belt 151. The conveyor 150 is configured so that the fibrous activated carbon 41 deposited on the belt 151 is transported toward the rollers 160 as the belt 151 rotates.

[0080] The roller 160 is disposed above the belt 151. The roller 160 is configured to be rotatable around a rotation shaft 161. The roller 160 is configured to press the activated carbon fiber 41 deposited on the belt 151 toward the belt 151.

[0081] In the molding process, as shown in Fig. 5A, the activated carbon fiber 41 is deposited on the upper surface of the belt 151. As the belt 151 rotates, the activated carbon fiber 41 is transported toward the roller 160, and is pressed toward the belt 151 by the roller 160. This results in a sheet-like intermediate molded body 43. The thickness T of the intermediate molded body 43 is the same as the equivalent diameter D of the third adsorbent 4C. That is, in the molding apparatus 100C, the roller 160 is disposed between the roller 160 and the upper surface of the belt 151 at a distance corresponding to the equivalent diameter D of the third adsorbent 4C.

[0082] 5B, in the process of pressing the activated carbon fiber 41, the fibers of the activated carbon fiber 41 tend to be oriented perpendicular to the pressing direction W3. Therefore, the intermediate molded body 43 formed by molding tends to contain a large amount of activated carbon fiber 41 oriented perpendicular to the pressing direction W3.

[0083] (cutting process) In the cutting process, the intermediate compact 43 formed by the molding process is cut to a dimension S3 corresponding to the length L of the third adsorbent 4C and formed into a columnar shape. In Figure 5B, an example of the cutting line is shown by a two-dot chain line. By forming the intermediate compact 43 into a columnar shape, the third adsorbent 4C is obtained, as shown in Figure 5C. The third adsorbent 4C formed through the molding and cutting processes tends to contain a large amount of fibrous activated carbon 41 oriented perpendicular to the pressing direction W3.

[0084] <Placement process> The arrangement process of the third embodiment is the same as the arrangement process of the first embodiment, except that in the third embodiment, the suction direction W1 in the first embodiment is replaced with a pressing direction W3.

[0085] [3-2. Effects] According to the third embodiment described above in detail, for the same reasons as those described in (2a) above, the same effects as those in (1a) above can be obtained. Furthermore, the same effects as those in (1c) and (1d) above can also be obtained. Note that the word "suction" in (1c) above should be read as "pressure," and the suction direction W1 should be read as "pressure direction W3."

[0086] 4. Other Embodiments Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take on various forms.

[0087] (4a) In the above embodiment, the equivalent diameter D of the third adsorbent 4C is larger than the length L, but the equivalent diameter D does not necessarily have to be larger than the length L. For example, the equivalent diameter D of the third adsorbent 4C may be equal to the length L.

[0088] (4b) In the above embodiment, the atmospheric port 2C is directly connected to the third adsorption chamber 33. However, the third adsorption chamber 33 may be connected to the atmospheric port 2C via, for example, another chamber. In other words, another chamber may be provided between the third adsorption chamber 33 and the atmospheric port 2C.

[0089] (4c) The function of one component in the above embodiments may be distributed among multiple components, or the functions of multiple components may be integrated into one component. Also, part of the configuration of the above embodiments may be omitted. Furthermore, at least part of the configuration of the above embodiments may be added to or substituted for the configuration of another of the above embodiments.

[0090] [Technical idea disclosed in this specification] [Item 1] A method for manufacturing a canister having an activated carbon molded body that adsorbs evaporated fuel generated in a fuel tank of a vehicle and an adsorption chamber that accommodates the activated carbon molded body, comprising: pressing or sucking the fibrous activated carbon in a predetermined direction to form a columnar activated carbon molding; placing the formed activated carbon molded body in the adsorption chamber so that a pressing or suction direction of the activated carbon molded body is perpendicular to a flow direction of the evaporated fuel; A method for manufacturing a canister, comprising:

[0091] [Item 2] A method for manufacturing the canister according to item 1, A method for manufacturing a canister, wherein a dispersion liquid in which the fibrous activated carbon is dispersed is placed in a mold having a bottom wall formed with a plurality of through holes, and the dispersion liquid is sucked toward the bottom wall, thereby forming the activated carbon molded body.

[0092] [Item 3] A method for manufacturing a canister according to item 1 or 2, The method for manufacturing a canister, wherein the activated carbon molded body disposed in the adsorption chamber has an equivalent diameter in a cross section perpendicular to a flow direction of the evaporated fuel that is larger than a length along the flow direction of the evaporated fuel.

[0093] [Item 4] A method for manufacturing a canister according to any one of items 1 to 3, In the method for manufacturing a canister, the outer peripheral surface of the activated carbon molded body disposed in the adsorption chamber, which surrounds the direction of flow of the evaporated fuel, is in contact with the inner surface of the adsorption chamber.

[0094] [Item 5] A method for manufacturing a canister according to any one of items 1 to 4, The adsorption chamber is connected to an atmospheric port that is open to the atmosphere. [Explanation of symbols]

[0095] 1...canister, 2A...charge port, 2B...purge port, 2C...atmospheric port, 3...case, 31...first adsorption chamber, 32...second adsorption chamber, 33...third adsorption chamber, 34...communicating portion, 4A...first adsorbent, 4B...second adsorbent, 4C...third adsorbent, 41...fibrous activated carbon, 42...dispersion liquid, 100A...molding device, 110...molding mold, 111...recess, 112...bottom wall, 113...side wall, 114...through hole, 120...suction portion.

Claims

1. A method for manufacturing a canister having an adsorption chamber, and an activated carbon molding housed in the adsorption chamber and configured to adsorb evaporated fuel generated in a vehicle fuel tank, the activated carbon molding having an equivalent diameter in a cross section perpendicular to the flow direction of the evaporated fuel that is greater than the length along the flow direction of the evaporated fuel, a step of placing the activated carbon fiber in a mold having a bottom wall and a side wall extending from the entire periphery of the bottom wall to one side of the bottom wall, wherein two portions of the side wall on the inner surface thereof face each other with a gap corresponding to the length, and pressing or sucking the activated carbon fiber toward the bottom wall to form the activated carbon molding into a columnar shape; placing the formed activated carbon molded body in the adsorption chamber so that the pressing or suction direction of the activated carbon molded body is perpendicular to the flow direction of the evaporated fuel; Equipped with In the molding step, the fibrous activated carbon placed in the mold is pressed or sucked toward the bottom wall until its height from the bottom wall is reduced to a height greater than the gap and corresponding to the equivalent diameter, thereby forming the activated carbon molded body.

2. A method for manufacturing the canister according to claim 1, comprising the steps of: In the molding step, a dispersion liquid in which the fibrous activated carbon is dispersed is placed in a mold having a bottom wall formed with a plurality of through holes, and the dispersion liquid is sucked toward the bottom wall to remove water from the dispersion liquid, and the dispersion liquid is sucked toward the bottom wall until the height of the fibrous activated carbon dispersed in the dispersion liquid from the bottom wall is reduced to a height that is greater than the distance and corresponds to the equivalent diameter, thereby molding the activated carbon molded body.

3. A method for manufacturing a canister according to claim 1 or 2, comprising the steps of: In the method for manufacturing a canister, the outer peripheral surface of the activated carbon molded body disposed in the adsorption chamber, which surrounds the direction of flow of the evaporated fuel, is in contact with the inner surface of the adsorption chamber.

4. A method for manufacturing a canister according to claim 1 or 2, comprising the steps of: The adsorption chamber is connected to an atmospheric port that is open to the atmosphere.

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