Air intake suction device

Abstract

[Solution] An adsorbent material sheet product, including an adsorbent material sheet and at least one porous cover layer, is attached to an interior wall surface defined by an air intake. The adsorbent material sheet collects vapors, such as hydrocarbon vapors, from engine components, such as combustion chambers, injectors, carburetors, fuel ports, crankcases, or other engine components, thereby reducing evaporative emissions. In certain configurations, the adsorbent material sheet product includes edge seals that improve handling of the adsorbent material sheet during the manufacturing process.

Description

[Technical Field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 62 / 884,458, filed August 8, 2019, the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0002] Evaporative emissions from gasoline and other hydrocarbon fuels are a significant source of air pollution because various hydrocarbons contained in the fuel can form photochemical smog when exposed to sunlight. This smog compound, and the hydrocarbons themselves, not only exacerbate health effects for humans and animals but also cause environmental damage. Traditionally, these emissions are typically controlled by installing adsorption canisters in the fuel tanks of cars, trucks, and other vehicles. While the engine is not running, the adsorption canister absorbs excess hydrocarbon emissions from the fuel tank. Conversely, while the engine is running, the canister is purged with fresh air, which is then directed into the engine's air intake so that the purged fuel vapors can be burned by the engine.

[0003] However, vehicle fuel systems contain countless locations where hydrocarbon vapors can escape and contribute to evaporative emissions. Furthermore, tightening hydrocarbon emission limits are being enforced by many agencies, such as the Environmental Protection Agency (EPA). These realities mean that new methods for capturing hydrocarbon vapor emissions must be developed. Current efforts focus on incorporating adsorbent materials into the engine's air intake, otherwise in close proximity to the combustion chamber and fuel injectors, to further reduce hydrocarbon emissions emanating from the air intake manifold. To date, these have taken the form of small pouches of granular activated carbon or strips of paper to which powdered activated carbon has been added. The former suffers from concerns regarding dust generation, increased pressure drop, and insufficient utilization of the activated carbon inside the pouch. The latter suffers from activated carbon fouling from the papermaking process, thereby compromising performance and performance and incurring high costs. There is a need for improved adsorption devices for adsorbing and / or absorbing hydrocarbon vapors from vehicle air intakes. The prior art documents relevant to the invention of this application are as follows (including documents cited in the international phase after the international filing date and documents cited when the invention entered the national phase in other countries). 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[0004] In one embodiment, there is a vapor adsorbing air intake that includes an air intake that defines an interior wall surface and an adsorbent material sheet product located along and adjacent to the interior wall surface for interaction with the vapor. Such an arrangement is a "flow-over" type device.

[0005] In some embodiments, there is a vapor adsorbing air intake that includes an air intake that defines an interior chamber, and an adsorbent material sheet product located within the interior chamber and positioned to allow interaction with the vapor as it flows through the adsorbent material sheet product. Such an arrangement is a "flow-through" type device. These adsorbent material sheet products may be in the form of rolled or laminated adsorbent material sheets.

[0006] In one embodiment, there is a vapor adsorbing air intake section that includes an air intake section that defines an interior wall surface, and an adsorbent material sheet product that includes an adsorbent material sheet and at least one porous cover layer, the adsorbent material sheet product being positioned along and adjacent to the interior wall surface for interaction with vapor.

[0007] In another embodiment, the adsorbent material comprises a carbonaceous material.

[0008] In another embodiment, the carbonaceous material is selected from the group consisting of activated carbon, reactivated carbon, carbon nanotubes, graphene, and combinations thereof.

[0009] In another embodiment, the carbonaceous material is activated or reactivated carbon.

[0010] In another embodiment, the adsorbent material sheet comprises an adsorbent material and a binder, 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, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof.

[0011] In another embodiment, each of the at least one porous cover layer comprises polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylate, UV-curable methacrylate, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof.

[0012] In another embodiment, the porous cover layer is in the form of a nonwoven fabric.

[0013] In another embodiment, the vapor adsorption air intake is at least one of an air filter box or housing, an air intake pipe, a mass airflow sensor, a throttle body, an air intake manifold, an air intake runner connected to an individual cylinder or combustion chamber, or an air intake runner connected to multiple cylinders or combustion chambers.

[0014] In another embodiment, the sheet of adsorbent material has an edge seal disposed on one or more of the peripheries of the sheet of adsorbent material or proximate the attachment of the sheet of adsorbent material to the interior wall surface of the air intake.

[0015] In another embodiment, the edge seal has an edge seal width of from about 1 mm to about 10 mm.

[0016] In another embodiment, the edge seal has an edge seal width of from about 2.5 mm to about 5 mm.

[0017] In another embodiment, the edge seal is formed on one or more portions of the one or more porous cover layers by at least one of localized heating by infrared radiation, ultrasonic vibration, or contact with a heated tool, localized curing or localized crosslinking by ultraviolet radiation or oxidizing or free radical compounds, localized application of an adhesive or bonding agent, or mechanical fastening by at least one of stitching, creasing, stapling, or clamping.

[0018] In one embodiment, there is an adsorbent material sheet product comprising at least one adsorbent material sheet and at least one porous cover layer disposed on the at least one adsorbent material sheet, the adsorbent material sheet product having an edge seal disposed on one or more of the peripheries of the adsorbent material sheet or proximate an attachment portion for attachment of the adsorbent material sheet to an interior wall surface of a vapor adsorbing air intake section.

[0019] In another embodiment, the edge seal has an edge seal width of from about 1 mm to about 10 mm.

[0020] In another embodiment, the edge seal herein has an edge seal width of from about 2.5 mm to about 5 mm.

[0021] In one embodiment, there is a method of making an adsorbent material sheet product, the method including: mixing a binder and an adsorbent material; forming at least one adsorbent material sheet from the mixture of the binder and the adsorbent material; providing a mounting portion on the adsorbent material sheet for mounting the adsorbent material sheet to an interior wall surface of a vapor-adsorbing air intake; providing a porous cover layer on the at least one adsorbent material sheet; and forming an edge seal disposed on one or more of the peripheries of the adsorbent material sheet product or proximate the mounting portion for mounting the adsorbent material sheet to the interior wall surface of the vapor-adsorbing air intake.

[0022] In another embodiment, the edge seal is formed by localized heating by infrared radiation, ultrasonic vibration, or contact with a heated tool; localized curing or localized crosslinking by ultraviolet radiation or oxidizing or free radical compounds; localized application of an adhesive, binder, pressure sensitive adhesive, or primer; mechanical fastening by at least one of stitching, creasing, stapling, or clamping; and combinations of two or more of the foregoing processes.

[0023] In one embodiment, there is a method of capturing vapors within a vapor adsorption air intake, the method including: providing an air intake defining an interior wall surface and an adsorbent material sheet product, the air intake including an adsorbent material sheet and at least one porous cover layer located along and positioned along the interior wall surface; and allowing vapors to contact the adsorbent material sheet product, thereby being adsorbed by the adsorbent material sheet product.

[0024] In another embodiment, the method further comprises desorbing vapors previously adsorbed by the adsorbent material sheet product by contacting the adsorbent material sheet product with a purge gas.

[0025] In one embodiment, a sheet of adsorbent material includes an air intake defining an interior wall surface, an adsorbent material, and a binder, the binder being selected from the group consisting of polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV curable acrylate, UV curable methacrylate, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), and a sheet of adsorbent material that is aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof, wherein the sheet of adsorbent material is located along and adjacent to the interior wall surface and positioned for interaction with vapors. [Brief explanation of the drawings]

[0026] [Figure 1] 1 illustrates one embodiment of the present invention utilizing an adsorbent core. [Figure 2] 1 illustrates a further embodiment of the present invention utilizing an adsorbent core. [Figure 3] 10 illustrates a further embodiment of the present invention utilizing a spacer. [Figure 4] 10 illustrates a further embodiment of the present invention utilizing a spacer. [Figure 5] 1 illustrates a test setup for an embodiment of the present disclosure. [Figure 6] 1 shows test results of embodiments of the present disclosure. [Figure 7] 1 illustrates an exemplary edge-sealed absorbent material sheet product according to one embodiment. [Figure 8] 1 illustrates another exemplary edge-sealed absorbent material sheet product according to one embodiment. [Figure 9] 1 shows test results of embodiments of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0027] Before describing the compositions and methods of the present invention, it is to be understood that the invention is not limited to the particular processes, compositions, or methodologies described, as these may vary. It is also to be understood that the terminology used in the description is for the purpose of describing particular versions or embodiments only, and is not intended to limit the scope of the present invention, which is limited only by the appended claims. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one 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, the preferred methods, devices, and materials are described herein. All publications mentioned herein are incorporated by reference in their entirety. Nothing herein should be construed as an admission that the invention is not entitled to antedate such disclosure by virtue of prior invention.

[0028] Also, it should be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include the plural forms unless the context clearly dictates otherwise. Thus, for example, reference to a "combustion chamber" is a reference to "one or more combustion chambers" and equivalents thereof known to those skilled in the art, and so forth.

[0029] As used herein, the term "about" means plus or minus 10% of the numerical value with which it is used. Thus, about 50% means a range of 45% to 55%.

[0030] As used herein, the term "sorbent material" is meant to encompass all known materials from any source that are capable of absorbing or adsorbing liquids and / or gases. For example, sorbent materials include, but are not limited to, carbon-based materials such as activated carbon, reactivated carbon, carbon nanotubes, or graphene. Other sorbent materials that are not carbonaceous include natural and synthetic zeolites, silica, silica gel, alumina, zirconia, and diatomaceous earth. In certain embodiments, the sorbent material is activated carbon.

[0031] As used herein, describing or claiming multiple sheets of adsorbent material means that there are multiple separate sheets with sides and / or surfaces adjacent to one another. Alternatively, describing or claiming multiple sheets of adsorbent material means that there is only a single sheet, but that it is rolled or folded onto itself to result in a stacked, rolled, or otherwise constructed mass of sheets with sides and / or surfaces adjacent to one another. The term also contemplates multiple sheets being stacked together and then rolled or otherwise folded to form alternating layers in a single mass.

[0032] When used in the context of an adsorbent or adsorbent material or adsorbent material sheet, the term surface refers to the exterior of that individual component. Even more specifically, in the context of an adsorbent material sheet, the term surface refers to the largest planar surface of the sheet, which faces each other or itself when rolled or stacked. In a sheet, the surface is significantly greater than the thickness of the sheet.

[0033] Embodiments of the present invention are directed to one or more sheets of adsorbent material, devices containing sheets of adsorbent material, and methods for making sheets of adsorbent material and devices containing these sheets. In various embodiments, the sheets of adsorbent material may be composed of an adsorbent material and a binder and may have a thickness of less than about 2 mm, or less than about 1 mm. The devices of various embodiments may include a housing and one or more sheets of adsorbent material. In some embodiments, the device may have a porosity of about 10% or more of the total volume of the housing.

[0034] Through the use of specific fiber-forming binders, activated carbon sheets can be produced with activated carbon contents of about 80% to about 90% by weight or more. Furthermore, the activated carbon is not contaminated by the binder (i.e., its pores are not blocked and its capacity is not reduced), thereby resulting in much higher capacity and faster speeds compared to the use of traditional papermaking techniques. The flexibility of the sheets allows for a wide range of design flexibility, allowing not only flow-through but also flow-by designs with variable pressure drop and capacity as needed. Exemplary sheets are described below. The sheets are suitable for lamination with a variety of other materials, which does not bond the sheets, facilitates installation of the sheets within manifolds (e.g., by sonic welding or heat caulking), and eliminates all concerns about fugitive dust.

[0035] Adsorption material sheet The adsorbent material sheets of the present invention may include some of the adsorbent materials described above, including, but not limited to, carbon-based materials such as activated carbon, carbon nanotubes, or graphene. Other adsorbent materials that are not carbonaceous include natural and synthetic zeolites, silica, silica gel, alumina, zirconia, and diatomaceous earth. In certain embodiments, the adsorbent material sheets include activated carbon. Adsorbents may be used alone or in combination.

[0036] Activated carbon may be available in a variety of grades and types, selected based on performance requirements, cost, and other considerations. It may be granular, resulting from powder re-agglomeration, crushing, or sizing; wood, coal, or pellets produced by extrusion; or activated carbon in powder form. Activated carbon may be formed and activated through a process called carbonization. Raw materials such as wood, nutshells, coal, pitch, and coconut are oxidized, demineralized, and / or carbon dioxide gasified with steam and activated to form a pore structure in the activated carbon useful for adsorption. The initial oxidation and demineralization process may include chemical treatment with dehydrating chemicals such as phosphoric acid, sulfuric acid, sodium hydroxide, potassium hydroxide, and combinations thereof.

[0037] Various activation processes are known in the art. The most useful process for providing activated carbon for the adsorbent material sheets of the claimed invention involves providing wood and / or wood by-products, acid treating the wood and / or wood by-products by exposure to phosphoric acid, and carbonizing the wood and / or wood by-products using steam and / or carbon dioxide gasification. This process results in activated carbon particles with the highest butane working capacity (BWC), a measure of activated carbon performance.

[0038] Activated carbon can be formed from materials including wood such as bagasse, bamboo, coconut husk, peat, hardwood and softwood sources in the form of sawdust and scrap, lignite, synthetic polymers, coal and coal tar, petroleum pitch, asphalt and bitumen, corn leaves and husks, wheat straw, spent grain, rice husks and husks, nut shells, and combinations thereof.

[0039] The absorbent material sheet may further include one or more binders. Embodiments are not limited to specific binders, which may include polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV-curable acrylates, UV-curable methacrylates, thermosetting divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers such as perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubbers (FEPM), aramid polymers and meta-aramid polymers such as para-aramid, 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 binder may be thermoplastic or thermosetting depending on the requirements and may include a mixture of thermoplastic and thermosetting compounds.

[0040] The one or more binder forms include one or more of a liquid binder having some associated viscosity or rheological properties, elongated fibers that are woven or nonwoven, or particles. In some embodiments, the binder comprises more than one of the above physical forms that are mixed together so that the resulting mixture is substantially homogeneous.

[0041] The amount of binder may be from about 1% to about 40% by weight of the total composition, and in certain embodiments, the amount of binder may be from about 1% to about 20% by weight or from about 2% to about 10% by weight of the total composition, or any individual amount or range including these exemplary amounts. The binder may be present in an amount of about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, or any range created from any two or more of the foregoing amounts, all measured by weight of the total composition. In some embodiments, the adsorbent material sheet may include a solvent, which may generally be present in small residual amounts, e.g., less than 10%, less than 5%, or less than 2%, and greater than about 0.1% or 0.2% by weight. In particular, in some embodiments, the adsorbent material sheet may be solvent-free (0%).

[0042] In some embodiments, the thickness of the adsorbent material sheet is less than about 3 mm, less than about 2.8 mm, less than about 2.6 mm, less than about 2.4 mm, less than about 2.2 mm, less than about 2.0 mm, less than about 1.8 mm, less than about 1.6 mm, less than about 1.4 mm, less than about 1.2 mm, less than about 1.0 mm, about 0.01 mm to about 2 mm, about 0.01 mm to about 1.8 mm, about 0.1 mm to about 1.6 mm, about 0.01 mm to about 1.4 mm, about 0.01 mm to about 1.2 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 exemplary ranges. The adsorbent material sheet of various embodiments has a density of about 0.05 g / cm. 3 ~Approx. 2.0g / cm 3 In other embodiments, the sheet of adsorbent material may have a density of 0.08 g / cm 3 ~Approx. 1.5g / cm 3 density of approximately 0.1 g / cm 3 ~Approx. 1.3g / cm 3or any density or range encompassed by these exemplary ranges. Density is calculated by first measuring the thickness of a given square or circular piece of sheet with a micrometer, multiplying by the surface area to get the volume, and weighing the piece to get the density (weight / volume).

[0043] The BWC of each adsorbent sheet is approximately 7g / 100cm 3 In some embodiments, the BWC may be greater than about 7.0 g / 100 cm. 3 ~About 30g / 100cm 3 , about 8.0g / 100cm 3 ~About 25g / 100cm 3 , about 10g / 100cm 3 ~About 20g / 100cm 3 , about 10g / 100cm 3 ~About 15g / 100cm 3 , about 11g / 100cm 3 ~About 15g / 100cm 3 , about 12g / 100cm 3 ~About 15g / 100cm 3 , or any individual BWC or range encompassed by these exemplary ranges. In other examples, the BWC is about 9 g / 100 cm 3 ~About 15g / 100cm 3 , about 12g / 100cm 3 ~About 20g / 100cm 3 , about 13g / 100cm 3 ~About 20g / 100cm 3 , about 14g / 100cm 3 ~About 20g / 100cm 3 , or approximately 15g / 100cm 3 ~About 20g / 100cm 3 It is also contemplated that any of the above range endpoints may be combined to form new, separate ranges.

[0044] As mentioned above, butane working capacity (BWC) is a measure of the performance of activated carbon. BWC is determined for a sample by measuring the activated carbon's ability to adsorb and desorb butane from dry air under specified conditions, 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 ASTM International and known to those skilled in the art. Specifically, testing can be in accordance with ASTM D5228, including revisions D5228-16, D5228-92(2015), D5228-92(2005), and D5228-92(2000).

[0045] It should be noted that in addition to the BWC testing methods described above, additional tests corresponding to various configurations can be performed. For example, the overall performance of adsorbents or adsorbent materials installed within vehicle fuel systems is subject to various tests by government agencies, such as the U.S. Environmental Protection Agency (EPA). Such tests include, but are not limited to, tests conducted in a SHED test chamber to determine one or more of static loss, running loss, and hot soak. Such tests may be diurnal in configuration to determine static loss, for example.

[0046] Adsorbent material sheets of embodiments can be made by any suitable process. In some embodiments, adsorbent material sheets can be made by grinding granular or pelletized adsorbent material into a powder, mixing the powder with a binder to form a mixture, mixing the mixture, optionally heating, and rolling the mixture to form an adsorbent material sheet. The grinding step can produce adsorbent particles having an average particle diameter of 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 individual particle diameter or range encompassed by these exemplary ranges; in certain embodiments, the ground adsorbent particles can have an average particle diameter of about 0.001 mm to about 0.01 mm. The step of mixing the powder with a binder can include mixing the adsorbent particle powder in an amount of about 2% to about 20% by weight or about 2% to about 10% by weight of the total composition, or any individual amount or range encompassed by these exemplary ranges. Heating can be carried out at any temperature sufficient to remove residual solvent, such as, for example, from about 50°C to about 200°C.

[0047] The adsorbent material sheets of the present invention may contain a variety of particle size distributions to increase the packing efficiency of the powder within the adsorbent material sheet. The selection of different particle sizes may also improve the rheological properties of the powder and surrounding binder, thereby allowing for improved mixing and uniform particle distribution prior to the formation of the adsorbent material sheet. In some embodiments, the particles of the adsorbent material sheet may have a single particle size distribution, while in other embodiments, the particles may have two different particle size distributions. In further embodiments, the particles may have at least three different particle size distributions.

[0048] The average particle sizes of at least two different particle populations, each having a particular size distribution, may be selected so that they have a ratio of about 1:1 to about 1:15. In other embodiments, the average particle sizes of the two different particle populations may have a ratio of about 1:2 to about 1:10. The average particle sizes may also have a ratio of about 1:2 to about 1:5, or any combination of the ratios listed above.

[0049] Adsorbent material sheets can be configured together in a variety of ways depending on the physical space they must fit into, the required device performance, and the features to be included adjacent to the sheets. In some embodiments, the sheets may be corrugated, contain folds, and / or contain holes or openings to increase the surface area of ​​the adsorbent material sheets exposed to passing fluids, thus increasing performance for a given total sheet surface area. Various corrugations, folds, holes, and openings can also be sized and positioned for internal and external features such as fluid channels, tubing, sensors, and valves. The folds in the adsorbent material sheets can take various forms, such as a spirally wrapped configuration in either a cylindrical or elliptical shape. The folds can also be in the form of an "S" shape or a convex or concave "C" shape, depending on the required device dimensions and / or some other required internal or external feature. Adsorbent material sheets can also be stacked in flat or curved configurations, and the stacked sheets can be square, rectangular, circular, oval, or other irregular shapes as needed to fit the intended space. This, along with the texturing, in combination with the housing features discussed below, allows devices formed from the adsorbent material sheet to fit within the confines of vehicle air intakes, air filters, air filter boxes, manifolds, intake runners, and other parts of a vehicle's air intake system.

[0050] In addition to the configurations described above, the adsorbent material sheet may also have surface features. In some embodiments, the adsorbent material sheet may include raised portions, while in other embodiments, the adsorbent material sheet may include depressed portions. These surface features may be combined within the same sheet. The inclusion of raised and / or depressed portions within sheets may be used to form various configurations between sheets, such as when the sheets are stacked and packaged. For example, sheets may be aligned so that the raised and / or depressed portions nest within each other, thereby bringing adjacent sheets closer together. Sheets may also be aligned so that the raised and / or depressed portions do not nest within each other, thereby forming gaps between adjacent sheets. Alignment may be used to form various open and closed channels for vapor adsorption between sheets.

[0051] The performance of carbon sheets can be improved by adding materials before or during sheet processing. These materials provide beneficial properties, such as increased porosity or enhanced adsorption of inorganic vapors, such as H2S or other volatile gases. Alternatively, different adsorbent materials can be simultaneously processed into a single sheet with distinct sections or performance gradients from one side of the sheet to the other.

[0052] Examples of additives that provide porosity include, but are not limited to, foam-like polymer additives, water-soluble polymers that can be rinsed to leave pores, friable materials with particle sizes larger than the intended thickness of the sheet that exfoliate and leave pores, thermally unstable materials so that heating the sheet evaporates the added material and creates pores in the sheet, and other similar processes that can impart controlled porosity within the adsorbent sheet, any of which may be used alone or in combination.

[0053] An alternative enhancement to sorbent sheet production is to process the sorbent sheet so that two or more sorbents with different properties are contained in a single sheet but separated along the width of the sheet. For example, a high BWC sorbent can be used in the same sheet with a low BWC sorbent so that vapors from a fuel tank discharge contact the high BWC sorbent before the low BWC sorbent in a single chamber. That is, in some embodiments, the low and high BWC sorbents can be homogeneously mixed, or in some embodiments, there can be separate sections of low or high BWC sorbent, if desired.

[0054] Another example is a high BWC adsorbent for the adsorption of butane, for example, contained in an adsorbent that removes H2S or other undesirable vapors that are not normally well removed by high BWC activated carbon.

[0055] Adsorbent sheet products In certain embodiments, a sheet of adsorbent material (such as Calgon Carbon's CALFLEX) is produced as described above and laminated or otherwise attached to a backing sheet to form the adsorbent material sheet product. The backing sheet can be any polymeric material that is capable of supporting the adsorbent material sheet while allowing the entire adsorbent material sheet product to be secured to various components of a vehicle's air intake system, without limitation.

[0056] The above-described adsorbent material sheets are incorporated into adsorbent material sheet products. The combination of adsorbent material sheets utilizes one or more of the above-described characteristics, such as increased surface area / volume ratio, reduced void space, and improved adsorbent performance. Typically, individual adsorbent material sheets are arranged next to each other to form an adsorbent material sheet product, which includes sheets that are stacked, rolled, wound, folded, and / or laminated so that the surfaces of the adsorbent material sheets are close to or adjacent to each other. Regardless of the arrangement, the goal is to maximize the surface area of ​​the sheets exposed to the vapor, fluid, and / or gas stream, and therefore maximize the performance of the adsorbent material sheets.

[0057] In some embodiments, the backing sheet is formed from polyester, polyethylene, low and high density polyethylene, polypropylene, polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF2 or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV curable acrylates, UV curable methacrylates, thermoset divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers, perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymers, para-aramid polymers, meta-aramid polymers, polytrimethylene terephthalate, ethylene acrylic elastomers, polyimide, polyamide-imide, polyurethane, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, any hydrocarbon permeable membrane, and copolymers and combinations thereof. Any of the above materials, which may be woven or nonwoven fabrics.

[0058] The backing sheet may have any construction, including extruded sheets, nonwoven sheets, woven sheets, cast sheets, injection molded sheets, and combinations thereof.

[0059] In some embodiments, the backing sheet is formed of the same material as the binder of the sheet of adsorbent material. In other embodiments, the backing material is formed of a different material than the binder of the sheet of adsorbent material.

[0060] The structure and method for attaching the adsorbent material sheet to the backing sheet to form the adsorbent material sheet product are not particularly limited. In some embodiments, the adsorbent material sheet is laminated by passing the adsorbent material sheet and the backing sheet through a roll mill. In other embodiments, the adsorbent material sheet and the backing sheet are coextruded from a single extrusion die. In other embodiments, the adsorbent material sheet and the backing sheet are bonded together by at least one layer of adhesive or by the surface energy of at least one of the adsorbent material sheet or the backing sheet. In some embodiments, the adsorbent material sheet and the backing sheet are bonded together by positioning a double-sided adhesive substrate between the adsorbent material sheet and the backing sheet. In some embodiments, the adsorbent material sheet may be edge-sealed to the backing sheet or encapsulated between the sheets; in some examples, the membrane is sealed past the carbon, i.e., the carbon is within a pocket formed by the backing material. In some embodiments, the carbon sheet may be laminated completely, partially, or within the boundary of the laminate. That is, if they do not extend to the edges of the device, in still further embodiments, the sheet of adsorbent material and the backing sheet are attached by sonic welding or mechanical fasteners, including staples, screws, nails, clamps, tabs, or posts. In some embodiments, a backing sheet may be provided on either side of the sheet of adsorbent material. Similarly, in some embodiments, separate sheets of adsorbent material may be disposed on both sides of the backing sheet. In still other embodiments, multiple alternating layers of sheets of adsorbent material and backing sheets may be used.

[0061] In some embodiments, the backing sheet may be omitted entirely, and the adsorbent material sheet product itself may be used directly, either alone or with a fastener or adhesive backing. In one embodiment, the adsorbent material sheet product comprises an adsorbent material sheet having an adhesive on one side for fastening directly to the air intake. In such an embodiment, the adsorbent material sheet product may be provided with a release liner to protect the adhesive prior to application to the air intake.

[0062] In some advantageous embodiments of the present disclosure, one or more of the adsorbent material sheet, the backing sheet, or both include a porous cover layer, which may include an "edge seal" to aid in the manufacturing, handling, and installation of the adsorbent material sheet or adsorbent material sheet products formed from one or more of the adsorbent material sheets. During the manufacturing, handling, and installation of conventional adsorbent sheets, particles of adsorbent material are often removed from the adsorbent material sheet. When these particles are removed, they create unwanted dust that can damage equipment, increase cleaning requirements, and potentially pose respiratory hazards. The porous cover layer, and optionally the associated edge seal, avoids this by providing areas of the adsorbent material sheet or adsorbent material sheet product where the edges of the sheet along the periphery are formed so that the adsorbent material cannot be peeled off. In some embodiments, one or more edges along the periphery are formed so that the adsorbent material is not contained in the binder, thereby ensuring that the material is not removed. By excluding the adsorbent material from these areas, it is ensured that the areas most frequently handled do not generate any dust during the handling and manufacturing of the adsorbent material sheet or adsorbent material sheet product. If the edge region of the adsorbent material sheet product does not have adsorbent material, it is formed by surrounding the adsorbent material sheet with a porous cover layer and then joining the porous cover layer together, extending beyond the edge of the adsorbent material, like a pouch.

[0063] The shape of the porous cover layer is not limited, so long as it is not damaged by vapors (such as hydrocarbon vapors) that the adsorbent material sheet product is expected to encounter and is sufficiently porous to allow those vapors to contact the adsorbent material within the adsorbent material sheet. The porous cover layer can be a nonwoven layer, a woven layer, a yarn layer, or a combination of one or more of the preceding embodiments. As for nonwoven layers, the present disclosure contemplates those made by, but not limited to, melt-blowing, spunbonding, flash-spinning, air-laying, batting, or fiberizing an existing sheet.

[0064] Alternatively, one or more edges along the periphery still contain the adsorbent material, but one or more porous cover layers are bonded together to prevent the adsorbent material from peeling off. In yet a further embodiment, one or more additional edge seal binders are added to the edge seal to ensure that the adsorbent material does not peel off. The composition of the porous cover layer or additional edge seal bonding agent includes, but is not limited to, 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, thermoset divinyl ethers, polybutylene terephthalate, acetal or polyoxymethylene resins, fluoroelastomers such as perfluoroelastomers (FFKM) and / or tetrafluoroethylene / propylene rubbers (FEPM), aramid polymers and meta-aramid polymers such as para-aramid, 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. In some embodiments, the edge seal binder is different from the binder present in the remainder of the adsorbent material sheet product. In some embodiments, the edge seal binder is the same as the binder present in the remainder of the adsorbent material sheet product. In yet other embodiments, the edge seal binder is the same as the porous cover layer.

[0065] In yet other embodiments, the edge seal is formed by further processing of one or more edges of the absorbent material sheet or backing sheet, referred to as an edge seal treatment. Edge seal treatments include, but are not limited to, one or more of: localized heating by infrared radiation, ultrasonic vibration, or contact with a heated tool; localized curing or localized crosslinking by ultraviolet radiation or oxidizing or free radical compounds; localized application of adhesives, binders, pressure-sensitive adhesives, or primers; mechanical fastening by at least one of stitching, creasing, stapling, or clamping; and combinations of the preceding techniques. However, it may also be understood that in certain embodiments, no edge seal treatment is performed, and the edge seal is formed by omitting absorbent material particles from the area of ​​the edge seal.

[0066] The configuration of the edge seal is not limited. In some embodiments, the edge seal extends around the entire perimeter of the adsorbent material without interruption. In other embodiments, the edge seal extends around the entire perimeter but is punctured by one or more of another adhesive layer, double-sided adhesive tape or substrate, heat caulking, sonic welding, or staples, screws, nails, clamps, tabs, posts, or holes used to attach the adsorbent material sheet to other adsorbent material sheets or another substrate. In still further embodiments, the edge seal does not extend around the entire perimeter but is present only in areas where handling is expected to occur. In further embodiments, the edge seal is present around an area of ​​the interior of the adsorbent material sheet that is used to attach the adsorbent material sheet to other adsorbent material sheets or other substrates.

[0067] The size of the edge seal is not limited and is measured by how far the edge seal extends inward from the edge of the adsorbent sheet, into the bulk of the adsorbent sheet, or outward from the edge of a device or fixture (e.g., a hole) that attaches the adsorbent sheet to another adsorbent sheet or external substrate. This size is referred to herein as the "edge seal width." The edge seal width can be about 1 mm, about 2 mm, about 2.5 mm, about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, about 9 mm, about 10 mm, about 15 mm, about 20 mm, about 25 mm, or about 30 mm, or any range formed by one or more of the above values. In certain embodiments, the edge seal width is about 1 mm to about 10 mm, or 1 mm to about 7 mm, or about 1 mm to about 5 mm, or about 2.5 mm to about 5 mm, or any combination of one or more of the foregoing ranges. An example of an edge seal and edge seal width is shown in Figures 6 and 7, where the edge seal formed by localized heating is present around the entire periphery of the sheet of adsorbent material and around the holes used to attach the sheet of adsorbent material to an external substrate, which is the surface of the air intake box.

[0068] In some embodiments, the adsorbent sheet product is rolled. The rolled adsorbent sheet product has a mass of about 7 g / 100 cm 3 The rolled adsorbent sheet product has a BWC of about 7.0 g / 100 cm 3 ~About 30g / 100cm 3 , or approximately 12g / 100cm 3 Over 13g / 100cm 3 Over 14g / 100cm 3 Over or about 15g / 100cm 3 Over 20g / 100cm 3 It has a BWC of approximately 10-20g / cm 3 , about 10~12g / cm 3 , about 10~14g / cm 3 , about 12~14g / cm 3 , about 12~15g / cm 3 , and about 15-20 g / cm3 Ranges such as are also contemplated.

[0069] The rolled adsorbent sheet products as described herein have a generally cylindrical shape with a length substantially greater than its diameter, but can adopt any dimensions, including conical, or frustoconical, as well as ellipsoidal, or other shapes.

[0070] The density of the rolled adsorbent sheet product can be calculated based on the following formula: [Table 1]

[0071] The rolled absorbent sheet product has a capacity of approximately 80 to 1500 kg / 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 approximately 700-750 kg / m 3 The wire can be wound to an average rolling density of 0.015.

[0072] The rolled absorbent sheet product is approximately 7g / 100cm 3 In some embodiments, the rolled adsorbent sheet product has a BWC of about 7.0 g / 100 cm 3 ~About 30g / 100cm 3 The rolled adsorbent sheet product may also have the same BWC as the unrolled adsorbent sheet product described above.

[0073] Similar to the discussion above regarding laminated sorbent sheets, the wound or rolled sorbent sheets may include a distribution of particle sizes or populations of sorbent pelletized or powdered activated carbon. As discussed above, the same ratios are contemplated. Similar to the discussion above, this allows for greater amounts of activated carbon to be incorporated into the sheets formed into the rolled sorbent sheet product, resulting in higher performance.

[0074] As used herein, a rolled or rolled sorbent sheet product refers to any form of layering of one or more sheets of sorbent material, such as by rolling up a tube (e.g., of any cross-sectional shape, such as circular, oval, square, triangular, rectangular, etc.), spiral rolling, concentric layering, or combinations thereof. For example, a single sheet of sorbent material may be spirally rolled along its length to form a cylindrically shaped rolled sorbent material sheet product. As another example, multiple sheets of sorbent material can be stacked and then rolled together to form a similar cylindrical shape. As another alternative, several sheets formed into a cylinder, each having a slightly different diameter from the next, can be arranged so that they form concentric circles with a cross-section of a similarly sized cylinder. Various combinations of these and other arrangements may be used to fill a space within a housing or canister or air intake of any shape, as described elsewhere herein.

[0075] When used in the context of rolled or rolled adsorbent material sheet(s), the term substantially parallel is used to mean that, in minute, infinitesimal dimensions, two sheets or portions of the same sheet are the same distance from each other in all directions. However, in the context of rolled or rolled adsorbent material sheets, particularly sheets that are single sheets spirally wound around a center or core, it is also understood to mean that the sheets are not exactly the same distance apart from each other over the entire area that they face each other. Furthermore, it is understood that this context contemplates similar variations in the distance between sheets due to components such as spacers, sensors, openings, tubes, ports, valves, channels, corrugations, pleats, folds, deformations that occur during manufacturing or operation, deformations due to shapes or pressures applied by or through external housings or air intakes, different packaging techniques such as sealing the periphery of the sheets, etc.

[0076] Similar to laminated sheet arrangements, rolled sorbent sheet products offer improved performance over equivalent amounts of activated carbon provided in pelletized or powder form.

[0077] The improved performance of the rolled sorbent sheet products of the present invention can be measured as the performance of a product having a given amount of activated carbon relative to the performance of the same amount and grade of activated carbon when provided in a canister in pelletized or powdered form. In some embodiments, the rolled sorbent 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 a canister in pelletized or powdered form. Ranges based on these amounts are also contemplated, such as about 5-16% higher performance, about 5-14% higher performance, about 10-14% higher performance, etc.

[0078] The adsorbent material sheets in the adsorbent material sheet product may be configured flat, spirally rolled into a cylindrical shape, oval rolled into an oval shape, elongated rectangular bar rolled into a folded shape, stacked in an "S" shape, formed as concentric cylinders, formed as concentric ellipses, formed as concentric rectangular bars, or a combination of these formats.

[0079] In some embodiments, the adsorbent material sheet product will comprise a single sheet of adsorbent material that is wound or rolled to achieve desired properties including, but not limited to, density, voids, pressure drop, capacity, etc.

[0080] Stacked Adsorbent Sheet Products: The stacked adsorbent sheet products of the present invention comprise two or more adsorbent sheets, each defining an upper surface and a lower surface and having a known combined total surface area, each adsorbent sheet comprising an adsorbent material and a binder, wherein adjacent adsorbent sheets are stacked and arranged such that adjacent upper and lower surfaces substantially conform to one another and are aligned to permit fluid flow at least between the adjacent upper and lower surfaces.

[0081] The improved performance of the laminated sorbent sheet products of the present invention can be measured as the performance of a product having a given amount of activated carbon relative to the performance of the same amount and grade of activated carbon when provided in a canister in pelletized or powdered form. In some embodiments, the laminated sorbent 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 volume and grade of activated carbon in a canister in pelletized or powdered form. Ranges based on these amounts are also contemplated, e.g., about 5-16% higher performance, about 5-14% higher performance, about 10-14% higher performance, etc.

[0082] Air intake In some embodiments, the adsorbent material sheet product, as described above in various embodiments, is part of an air intake. As used herein, the term "air intake" refers to any structure through which air or other oxidant passes before entering the combustion chamber of an engine. The choice of engine is not particularly limited and includes internal combustion engines operating using any known liquid fuel or external combustion engines operating using any known liquid fuel. In some embodiments, the engine is a gasoline engine found in automobiles, trucks, motorcycles, boats, watercraft, helicopters, aircraft, lawns, small displacement devices, ATVs, snowmobiles, snow blowers, other lawn equipment, and other small motorized devices. In other embodiments, the engine is a diesel engine found in vehicles, trucks, motorcycles, boats, watercraft, helicopters, or aircraft. In still other embodiments, the engine is a gas turbine engine found in vehicles, trucks, motorcycles, boats, watercraft, helicopters, or aircraft. The engine may operate on any fuel or combination of fuels, including gasoline, diesel, ethanol, kerosene, natural gas (methane), propane, butane, jet fuel, Jet A, Jet A-1, methanol, vegetable oil, biofuel, biodiesel, biogas, butanol, and combinations thereof.

[0083] When used in an air intake, the adsorbent material sheet product captures fuel vapors by contacting the adsorbent material sheet product with the fuel vapor, thereby causing the adsorbent material sheet product to adsorb the fuel vapor. After the fuel vapor is adsorbed, it can be desorbed by contacting the adsorbent material sheet product with a purge gas. The purge gas can include, but is not limited to, air, nitrogen, oxygen, an oxidant (e.g., nitrous oxide), water vapor, or any other gas that can pass through the adsorbent material sheet product and contain additional fuel vapor.

[0084] The adsorbent material sheet product may be attached or adhered to the interior or exterior of the air intake by any device, including but not limited to, an adhesive layer, double-sided adhesive tape or substrate, heat caulking, sonic welding, or mechanical fasteners, including staples, screws, nails, clamps, tabs, holes, or posts.

[0085] The adsorbent material sheet product may be placed anywhere within the air intake to absorb or adsorb hydrocarbon vapors that would otherwise escape from the combustion chamber, injectors, carburetor, fuel port, crankcase, or other engine components. In some examples, the adsorbent material sheet product is placed within an air filter box or housing, on or within an air filter, within an air intake duct, within a mass airflow sensor, within a throttle body, within an air intake manifold, within an air intake runner connected to an individual cylinder or combustion chamber, or within an air intake runner connected to multiple cylinders or combustion chambers. In some embodiments, a single adsorbent material sheet product is positioned within one of the above locations. In other embodiments, multiple adsorbent material sheet products are positioned within one or more of the above locations.

[0086] The laminated sorbent sheet product has a BWC that is at least 10% higher than the BWC of the same amount of pelletized / powdered form of sorbent material by volume in the sorbent sheet. The laminated sorbent sheet product has a BWC of about 7 g / 100 cm. 3 The laminated sorbent sheet product has a BWC greater than about 7.0 g / 100 cm 3 ~About 30g / 100cm 3 , or approximately 12g / 100cm 3 Over 13g / 100cm 3 Over 14g / 100cm 3 Over or about 15g / 100cm 3 Over 20g / 100cm 3 It has a BWC of approximately 10-20g / cm 3 , about 10~12g / cm 3, about 10~14g / cm 3 , about 12~14g / cm 3 , about 12~15g / cm 3 , and about 15-20 g / cm 3 Ranges such as are also contemplated.

[0087] In some embodiments, the stacked sheets are held in a spaced relationship that controls one or more of void volume, flow rate, pressure drop, and other properties. Such spacing is achieved in some embodiments in which at least one of the two or more sheets of adsorbent material is corrugated. Spacing can also be achieved by various folds within the sheets, or by corresponding raised and / or depressed portions of the sheets that are aligned to form gaps between the sheets. When the sheets are intentionally arranged so that the raised and / or depressed portions of the sheets do not nest between them, this provides additional spacing between the sheets, allowing fluid flow in those areas. When the sheets are intentionally arranged so that at least some raised and / or depressed portions nest between the sheets, this provides a tighter interlocking stack of the sheets, reducing the spacing between the sheets and correspondingly reducing or even halting fluid flow. A combination of these features can be used to form a stacked adsorbent sheet product with oriented regions or channels for fluid flow and barriers or edge seals to prevent fluid leakage. These features for fluid flow may also include holes, cuts, or openings through one or more of the sheets in the laminated sorbent sheet product.

[0088] Each adsorbent sheet defines opposing lateral edges that are substantially parallel to the fluid flow. The corresponding lateral edges of adjacent adsorbent sheets may be separated from one another, joined together, or some combination thereof. In this manner, the edges of the stacked adsorbent material sheet product may be sealed, partially sealed, or unsealed. The nature of the seal or unseal may be selected to achieve a desired result, such as modifying fluid flow rate and / or pattern or other characteristics.

[0089] In some embodiments, the laminated adsorbent material product provides a void volume of about 10% or more, about 12% or more, about 14% or more, about 15% or more, about 16% or more, about 17% or more, about 18% or more, about 19% or more, about 20% or more, about 21% or more, about 22% or more, about 23% or more, about 24% or more, about 25% or more, about 26% or more, about 27% or more, about 28% or more, about 29% or more, about 30% or more, or any range formed by combining the above ranges. In some embodiments, the laminated adsorbent material product provides a void volume of about 10%, about 12%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, about 20%, about 21%, about 22%, about 23%, about 24%, about 25%, about 26%, about 27%, about 28%, about 29%, about 30%, or any range formed by a combination of the above ranges. In some embodiments, the laminated adsorbent material product provides a void volume of about 10-15%, about 15-20%, about 20-25%, about 25-30%, or about 30-35%.

[0090] In some embodiments, each adsorbent sheet has a density of about 0.08 g / cm 3 ~Approx. 1.5g / cm 3 It has a density of

[0091] In some instances, the adsorbent sheet product comprises at least two populations of adsorbent material particles, each of which has a different average particle diameter. See the above discussion of bimodal particle size distribution with respect to individual adsorbent material sheets. For products formed from multiple adsorbent material sheets, the same distribution ratio between the populations of adsorbent particles is contemplated. In some instances, the density of adsorbent material particles achieved by the at least two populations is greater than the density achieved by either population alone. The inclusion of a bimodal particle size distribution can also be used to improve the mechanical properties of the adsorbent sheet product, making the polymer sheet much more resistant to shear forces.

[0092] In some instances, an adsorbent material sheet product comprises at least two adsorbent material sheets, each having defined upper and lower surfaces with a combined total surface area, 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 separate sheets are substantially parallel and aligned to permit fluid flow at least between the adjacent upper and lower surfaces.

[0093] The term substantially parallel as used in the context of a laminated adsorbent material sheet product means that the sheets maintain the same distance apart throughout their area, with exceptions made for various physical properties and characteristics. These exceptions within the scope of substantially parallel include, but are not limited to, differences due to variations in components such as spacers, sensors, openings, tubes, ports, valves, channels, corrugations, pleats, folds, variations occurring during manufacturing or operation, variations due to shape or pressure applied by or through an external housing or air intake, different packaging techniques such as sealing the perimeter of the sheets, etc.

[0094] In some embodiments, 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 volume of adsorbent material in pelletized or powder form. These may also be combined to form a range, for example, about 5-25% higher. The present invention also contemplates these amounts as range endpoints, such as at least about 40% higher.

[0095] Rolled / Rolled Adsorbent Material Sheet Products: Adsorbent material sheet products may also be rolled or rolled, alternatively or in combination with laminated embodiments. Rolled or rolled adsorbent material sheet products include adsorbent sheets defining upper and lower surfaces and bonded to have a known total surface area, where the adsorbent sheets include an adsorbent material and a binder, where the adsorbent sheets are spirally rolled to create adjacent sheet layers that allow fluid flow around and between adjacent sheet layers.

[0096] Additional Embodiments Additional embodiments are also contemplated. In one embodiment, the adsorbent material sheet product form is a rolled sheet comprising an adsorbent material sheet. In another embodiment, the adsorbent material sheet product form is a shredded sheet comprising shredded strips of an adsorbent material sheet. In another embodiment, the adsorbent material sheet product form is cut sheets of an adsorbent material sheet of various shapes. When the sheet is shredded or cut, the x and y dimensions of the sheet are greater than the thickness of the sheet.

[0097] In yet other embodiments, the sorbent is not in the form of a sheet product, but instead is in strands of binder and sorbent. The strands may be individually woven, nonwoven, or in other forms, including ropes or threads. These forms may be achieved by fiberizing the binder with the sorbent to form thin strands that are then combined into other forms.

[0098] Rolled sheets are typically made by winding a sheet around a solid, central, cylindrical spindle. This can be some solid polymer or other material. The spindle is solid and occupies a volume. In other instances, the sheet is wound around an open central core, such as a rigid or semi-rigid tube. In either case, the center does not contribute to the performance of the adsorption device. This application is directed toward making good use of that central core. Activated carbon sheets are wound around an adsorption core material, creating a spirally wound device with additional adsorption capacity.

[0099] The central core is made from the adsorbent material or as a structure that functions as a core with an internal volume filled with the adsorbent material. The advantage of this is to increase the amount of adsorbent in the device, thereby increasing performance. The central core can take the form of an open space, a hollow tube, a perforated hollow tube, or other structure used to define a space that holds additional adsorbent material. The increase in adsorbent material should further improve performance.

[0100] The central core may comprise not only the sheets described above, but also other forms of absorbent material such as cut or shredded sheets, ropes, threads and the like.

[0101] Another improvement relates to improved flow between the spirally wound sheet or sheets. Spiral winding of carbon sheets to form adsorbers has been achieved by controlling the tension of the winding process. Because the sheets are flexible and have low tensile strength, this can lead to inconsistent, difficult-to-control, or non-existent spacing between the wound sheets. The use of spacers, for example, in the form of woven or nonwoven fabrics, netting, or other fabrics, or by incorporating particles into the sheets with a diameter greater than the sheet thickness, results in a higher tensile strength material with a predefined spacing between the wound layers. The sheets can also be perforated to overcome the problem of inconsistent winding spacing by providing a pathway between the wound layers, thereby preventing carbon shielding and bypass.

[0102] Double-sided spacers can be incorporated into the spirally wound adsorber during the winding process. Separate double-sided spacers made from either polymer, fabric, metal, carbon fiber, or activated carbon fiber, or a combination thereof, are wrapped with the carbon sheet to form the final assembly. The spacers can be of different thicknesses to control the size and pressure drop across the adsorber. Spacer orientation can be used to control fluid flow in a path that is not necessarily the shortest distance, which increases fluid-carbon contact time. This also increases the tensile strength of the unit.

[0103] In some embodiments, the spacer can be a nonwoven porous material. The nonwoven porous material can be incorporated into a rolled structure that allows for uniform spacing with a controlled pressure drop. Tensile strength may also be improved.

[0104] To increase the tensile strength of the carbon sheet, polymeric or fibrous netting can be incorporated into the carbon sheet during the roll milling process. The netting can be of various configurations and thicknesses, depending on the desired properties of the final sheet. The goal is to increase the tensile strength of the material, allowing for more reliable rolling, while maintaining separation and ease of manufacturing.

[0105] Some embodiments achieve similar results by incorporating perforated sheets: the rolled adsorbent sheet can be perforated before rolling to mitigate imperfections in the rolling process and provide an alternative path for fluid flow through the adsorber.

[0106] Activated carbon in granular or pellet form can be used as a spacer rather than a woven or nonwoven material. Activated carbon, or some other hard granular material that is preferably an adsorbent material, can be added to the carbon sheet either before or after milling to act as a spacer and add adsorption capacity.

[0107] Any of these spacers can be used with stacked sheets as well as rolled sheets with the same benefits. In either configuration, the spacer creates uniform spacing. Textures such as corrugations or other surface features can also be employed to achieve desired characteristics and flow.

[0108] In some embodiments, various components, such as adsorbent material sheets, spacers, woven and / or nonwoven materials, perforated or non-perforated sheets, additional adsorbent materials, and other components, may be rolled in an alternating fashion, which may be referred to as a "jellyroll" configuration when the alternating components are parallel to one another and spiral around a repeating band core. This embodiment is most useful for embedding spacers or other pleated, textured, or corrugated components between adsorbent sheets, precisely controlling the spacing between sheets and therefore the pressure drop and performance. In still further embodiments, the components may be co-bonded together as tubes and not spirally wound. In further embodiments, the components may be layered as flat sheets or non-cylindrical shapes.

[0109] Various embodiments are illustrated in the figures. FIG. 1 illustrates the improvement of including a sorbent within a central core of a rolled sheet of sorbent material. In FIG. 1, rolled sheet of sorbent material 1 is shown as including a sheet of sorbent material 2 wrapped around a central core of sorbent 3. In another embodiment, FIG. 2 illustrates rolled sheet of sorbent material 1, again including a sheet of sorbent material 2 wrapped around a central core of sorbent 3. However, the embodiment of FIG. 2 further includes a tube 4 or other similar structure surrounding the sorbent 3. The tube 4 may include perforations, lacerations, openings, or other similar features (not shown) that allow at least some gas or vapor to pass between the sorbent contained in the central core and the sorbent sheet material in the outer portion.

[0110] In yet a further embodiment, Figure 3 shows a rolled adsorbent material sheet 1 comprising adsorbent material sheets 2, further including spacers 5 included to precisely control spacing, and therefore pressure drop, and other performance characteristics of the rolled sheets. Figure 4 shows an additional embodiment in which stacked adsorbent material sheets 6 include several stacked adsorbent material sheets 2. Between each pair of adsorbent material sheets 2 is a spacer 5 that is used to precisely control spacing, and therefore pressure drop, and other performance characteristics of the stacked sheets.

[0111] In some instances, the adsorbent material sheet product may be applied directly to a surface such as an air intake manifold, or may be selectively cured with an outer sheet to form a durable hardened shell that acts as a support for the rolled or folded adsorbent sheet. Such selective curing can be accomplished thermally or with a chemical bath, or by actinic radiation, e.g., ultraviolet light, or by electron beam curing.

[0112] In embodiments where the sheet of adsorbent material omits a housing, if it can be housed within a space where capture is required, such as an air intake manifold or associated pipework, the sheet of adsorbent material may be attached to these areas in various ways. In some embodiments, the sheet is heat-staked in the desired position and location. In some embodiments, the sheet of adsorbent material can be fastened using mechanical fasteners such as screws, rivets, or clamps, or the sheet of adsorbent material can be fastened using an adhesive backing. The adhesive backing may be a single-layer adhesive or double-sided adhesive tape or sheet. Adhesives used for the adhesive backing can include pressure-sensitive adhesives, UV-curable adhesives, heat-curable adhesives, hot-melt adhesives, and reactive multi-part adhesives. Adhesive compositions include acrylics and (meth)acrylics, acrylates and (meth)acrylates, epoxies in one- and two-part formulations, and urethanes.

[0113] The device of various embodiments can include a housing and a sheet of adsorbent material as described above. The housing can be any shape and can be configured to purify gas. For example, in some embodiments, the housing can be any shape, such as a cubic, cuboid, or cylindrical shape. The sheet of adsorbent material can be sized to fit within the housing and substantially fill the space within the housing through which the gas or liquid passes. In some embodiments, two or more sheets of adsorbent material can be stacked to substantially fill the housing, and in other embodiments, the sheets of adsorbent material can be rolled 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 arranged so that adjacent sheets are spaced apart. For example, in certain embodiments, the sheets can be corrugated, with the adsorbent material sheets forming a series of parallel ridges and grooves, and in some embodiments, the corrugated sheets of adsorbent material can be separated by flat or textured sheets of adsorbent material. The corrugated sorbent material sheets may be placed within the housing in a stacked or rolled / spiral wound configuration. Figures 7 and 8 show two exemplary sorbent products that can be applied within the air intake box.

[0114] Referring to Figure 7, a parallelogram-shaped adsorbent material sheet product 70 is shown according to one embodiment. The adsorbent material sheet product 70 includes an adsorbent material sheet product 71, which includes nonwoven polypropylene fibers and a PTFE binder, and holes 72 for use in mounting the sheet product 70 to an air intake box (not shown). Edge seals 73 are present along the periphery of the sheet product 70 and extend inward from the outer edge of the sheet product 70. Separate edge seals 74 are also present, extending outward from the outer edge of each hole 72.

[0115] Referring to Figure 8, a trapezoidal-shaped adsorbent material sheet product 80 is shown according to one embodiment. The adsorbent material sheet product 80 includes an adsorbent material sheet product 81, which includes nonwoven polypropylene fibers and a PTFE binder, and holes 82 for use in mounting the sheet product 80 to an air intake box (not shown). Edge seals 83 are present along the periphery of the sheet product 80 and extend inward from the outer edge of the sheet product 80. Separate edge seals 84 are also present, extending outward from the outer edge of each hole 82.

[0116] In various embodiments, the porosity may be about 30% to about 32% less than the void volume of current devices, and in some embodiments, the porosity may be as low as about 10%. For example, the device may have a porosity of about 45% to about 10%, about 35% to about 10%, about 25% to about 10%, or any individual porosity or range encompassed by these exemplary ranges. The devices of various embodiments may exhibit less flow restriction, e.g., pressure drop, than devices using granular or pelleted textured adsorbent materials. Thus, more adsorbent material can be incorporated into such devices without reducing the flow rate of the device.

[0117] Such an embodiment of the device has a mass of about 4.0 g / 100 cm 3 and in some embodiments, the device may have a BWC of greater than about 4.0 g / 100 cm 3 ~About 20g / 100cm 3 , 5.0g / 100cm 3 ~Approx. 18g / 100cm 3 , about 7.0g / 100cm 3 ~Approx. 16g / 100cm 3 , or approximately 8.0g / 100cm 3 ~About 15g / 100cm 3, or any individual BWC or range within these exemplary ranges. The device may exhibit a pressure drop up to equal that of a conventional densely packed bed of activated carbon or other active compound powder, pellets, or granules. This feature is advantageous because the adsorbent material sheet products of the present invention, whether stacked, rolled, wound, or otherwise configured, still have the same vapor and gas processing and transport capabilities as conventional devices, despite the improved adsorbent performance.

[0118] In some embodiments, an air intake manifold may include integrated vapor adsorption, including a manifold structure and at least one adsorbent sheet material product applied to an interior wall of the air intake manifold.

[0119] Additional Components The present invention may also include sensors, such as fuel composition sensors. The fuel composition sensor can be used to detect the mixture of gasoline and ethanol or other fuels contained within the housing or air intake and adsorbent material. This information can be transmitted to the ECU so that the vapors later released into the engine can be more accurately used during engine combustion. Other sensors include temperature sensors, vapor pressure sensors, oxygen sensors, etc. Sensors can operate based on principles such as electrochemical interaction, electronic (e.g., thermocouples), electromechanical, refractive index, or infrared spectroscopy, depending on the type of information required by the ECU. Sensors can be included singly or in combination within the housing or air intake, or, if no housing is specified, within the area containing the adsorbent material sheet. The sensor can be included in a hole or notch cut in the sheet, or in the space between the sheets, with the sheet wrapped or folded around the sensor.

[0120] Example 1: Air intake test To demonstrate the benefits of hydrocarbon adsorption over prior art product testing, butane was used as follows. Test setup: The airtight box contains an injection port and a port for the butane detection sensor. During testing, the sensor remains in the box and is zeroed before testing begins. Inject 1.25ml of butane into the box using a syringe. ●If a level of 1000 ppm is detected, place the sample in a box. ●When the test sample is placed in the box, the timer starts. • Measurements are taken at 5 minute intervals for the first 30 minutes, then every 10 minutes until the end of the test (120 minutes or until a reading of 0 ppm of butane is reached). The test setup is shown in Figure 5.

[0121] Referring to FIG. 5, a test apparatus 50 is shown. The test apparatus 50 includes a transparent acrylic box 51, one wall of which has a hole through which a sensor arm 52 is inserted with appropriate sealing and packaging material to ensure that gas does not leak out of the transparent acrylic box 51. Inside the transparent acrylic box 51, the sensor arm suspends a butane sensor 53 that detects the level of butane contained within the transparent acrylic box 51. An injection port 56 is also present so that butane or other gases can be added. A sample (not shown) is placed into the apparatus 50 by opening a door 54 by means of a handle 55.

[0122] The adsorbent sheets were formed by mixing powdered activated carbon and a PTFE binder. The binder was mixed in an amount of approximately 11% by weight. The powdered activated carbon is available from Calgon Carbon Corporation under the product name "RB," a coal-based activated carbon with a weight iodine count of at least 1070 mg / g. These adsorbent sheets were shown to reach undetectable butane levels faster than any other product tested, as shown in the graph below. The results are detailed in Figure 6.

[0123] Example 2: Determination of butane activity of activated carbon sheets from hydrocarbon adsorber (HCA) Butane activity (BA) is defined as the percentage of butane mass absorbed by an activated carbon sample when the carbon is saturated with butane under the conditions of the test method. The BA test may be used as a non-ozone depletion proxy in place of the CCI4 number test. If it is necessary to convert BA to a CCI4 number, factors correlating the two tests are provided. Butane working capacity (BWC) is defined as the difference between the butane adsorbed at saturation and the butane retained by the carbon per unit volume after a specified purge. This method is modeled according to ASTM D5742 and ASTM D5228.

[0124] An activated carbon bed of known volume and mass is saturated with butane vapor. The mass adsorbed at saturation is measured and reported on a percent basis as the mass of butane per unit mass of carbon. The carbon bed is then purged under specified conditions with dry hydrocarbon-free air. The mass loss is the BWC, expressed as the mass of butane per unit area of ​​carbon. The test conditions govern the adsorption of butane on the activated carbon. Deviations from the method may result in varying butane values. Test setup: • A 3.5" x 2.5" die cutting tool should be used to cut the specimens from the HCA. The strips of material cut from the parts are placed in an oven-safe tray. They are then oven dried at 105°C overnight. Weigh the empty dry sample tube to the nearest 0.01 gram and record the tare weight. Fill the column with the cut carbon strip sample. Reweigh the filled sample tube to the nearest 0.01 gram. Record the weight of the carbon and sample tube. Calibrate the butane adsorption apparatus. Set the water bath to maintain a temperature of 25 ± 0.2°C. Adjust the butane flow through the carbon bed at 250 ± 5 mL / min. Check the flow periodically as the sample is being measured. Place the filled sample tube in a constant temperature bath, connect a butane delivery line to the tube, and pass a butane downflow through the carbon bed for at least 20 minutes or until saturation is achieved. Carefully remove the sample tube from the instrument without damaging the floor, wipe it dry, and weigh it to the nearest 0.01 gram. After weighing the tube, return the sample tube to the constant temperature water bath and connect the air delivery line to the tube. Set the apparatus to provide a downflow of air through the carbon bed. The rotameter is adjusted to purge the sample with dry air at a rate of 300 ± 5 mL / min for 40 minutes ± 20 seconds. During the purge cycle, the weight is checked and recorded to the nearest 0.01 g every 10 minutes. After the purging time, remove the air, remove the tube, replace the stopper, remove the sample tube from the water bath, and allow it to dry. ●Weigh the tube to the nearest 0.01g and record the mass.

[0125] Example 3: ABC HCA Air Intake Box Butane / Purge Test In this test Butane adsorption cycle test setup: Record the pre-oven dry mass of the sample using an analytical balance and oven dry at 105°C for at least 3 hours or overnight. Select the air intake box for testing and set it up in the test station Turn on the butane and, using the flow meter, set the flow rate to 0.442 liters per minute (L / min). Once the flow rate is set, attach the butane hose line to the box. Place a pocket balance inside the box, place standoffs inside the box, and leave the door to the box open Remove the sample from the oven and record the mass using an analytical balance. ●Place the sample inside the box on top of the standoff inside the box. Close the door and lock it in tightly ● Conduct the test for 90 minutes At the end of the test, before removing the sample from the box, ensure that a Ziploc plastic bag with its mass recorded is prepared. After 90 minutes, remove the sample from the box and immediately pack it in a bag. Record the mass of the sample inside the bag. Subtract the mass of the bag from the total mass to record the final mass after the test. Air purge cycle test setup: Disconnect the butane line from the box to the previous butane adsorption cycle. ● Turn on the air valve ●Set the air flow rate to 23.70 L / min. Connect an air line to the box and use another air line to bleed any residual butane out of the box. Use a butane detection sensor to determine if there is any residual butane before removing the additional air line Set the flow rate, remove the butane-loaded sample from the plastic bag, and place it on the standoff in the box. ●Close the box door and close it tightly. During the first 30 minutes, remove the sample from the box and place it on the analytical balance every 5 minutes. After the first 30 minutes, repeat the mass recording every 10 minutes until a total test time of 120 minutes has been achieved. The final mass recorded will serve as the final mass after testing. Upon completion of the test, if no additional tests are being prepared, turn off the balance and shut off the gas flow (butane and air).

[0126] Example 4 Three experimental sets were saturated with butane vapor and then purged to determine the overall butane working capacity of the adsorbent sheet, the effect of different edge seal sizes on the overall butane working capacity of the adsorbent, and the relative performance of the adsorbent sheet compared to a conventionally used prior art carbon paper sheet. Testing was performed according to Example 3 above. The test results are shown in Table 1 below and Figure 9. In Table 1, each row labeled "Sample" is actually the average of multiple test runs, and the actual curves for each individual sample are shown in Figure 9. In each test, the overall adsorbent sheet product was the same size, but the depth of the edge seal varied. The edge seal was around the entire perimeter of the adsorbent sheet product. Sample CCC_RD_0070 had a larger overall sheet size and therefore a higher average butane adsorption result than CCC_RD_0068 and CCC_RD_0069. Samples CCC_RD_0068 and CCC_RD_0069 were compared to commercially available carbon paper of the same size commonly used in air intake evaporative adsorption applications. The adsorbent material sheet products of the three inventive samples were formed from a mixture of RB powdered activated carbon in an amount of 89 wt. % and a total amount of 11 wt. % of a PTFE binder with non-woven polypropylene fibers. [Table 2]

[0127] In the above detailed description, reference is made to the accompanying drawings, which form a part of this specification. In the drawings, like symbols typically identify like components unless the context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are expressly contemplated herein.

[0128] The present disclosure is not limited with respect to the specific embodiments described in this application, which are intended as illustrative of various aspects. As will be apparent to those skilled in the art, many modifications and variations can be made without departing from the spirit and scope thereof. Functionally equivalent methods and apparatuses within the scope of the present disclosure, in addition to those recited herein, will be apparent to those skilled in the art from the foregoing description. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that the present disclosure is not limited to particular methods, reagents, compounds, compositions, or biological systems, as these may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0129] With respect to the use of virtually any plural and / or singular term herein, those skilled in the art can translate from the plural to the singular and / or from the singular to the plural as appropriate to the context and / or application. Various singular / plural arrangements may be expressly set forth herein for clarity.

[0130] Those skilled in the art will understand that the terms used herein, and particularly in the appended claims (e.g., the body of the appended claims), are generally intended as "open" terms in general terms (e.g., the term "including" should be interpreted as "including, but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "including, but not limited to," etc.). Although various compositions, methods, and devices are described in terms of "comprising" various components or steps (interpreted as meaning "including, but not limited to"), the compositions, methods, and devices can also "consist essentially of" or "consist of" the various components and steps, and such terminology should be interpreted as defining an essentially closed group of members. It will be further understood by those skilled in the art that where a specific number of recitations of the introduced claims are intended, such intention will be explicitly recited in the claim; in the absence of such recitation, no such intention exists.

[0131] For example, as an aid to understanding, the following appended claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that introducing a claim recitation with the indefinite article "a" or "an" limits a particular claim containing such introduced claim recitations to embodiments including only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"). The same applies to the use of specific articles used to introduce claim recitations.

[0132] Furthermore, even if a particular number of enumerations in the introduced claims are explicitly recited, those skilled in the art will recognize that such enumeration should be interpreted to mean at least the number recited (e.g., without other qualifiers, meaning at least two enumerations, or more than two enumerations, e.g., a bare enumeration and "two enumerations"). Furthermore, in those instances where a convention similar to "at least one of A, B, and C, etc." is used, generally, such structure is intended in the sense that one skilled in the art would understand the convention (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems having A only, B only, C only, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). Moreover, in those instances where a convention similar to "at least one of A, B, or C, etc." is used, generally, such construction is intended in the sense that one of ordinary skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" includes, but is not limited to, systems having A only, B only, C only, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those of ordinary skill in the art that virtually any separate word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibility of including that word, either of those words, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

[0133] Furthermore, when features or aspects of the disclosure are described in terms of a Markush group, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0134] As will be understood by those skilled in the art, for any and all purposes, including providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations thereof. A recited range can be readily recognized as fully descriptive and allowing for the same range to be divided into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily divided into lower, middle, and upper thirds, etc. Also, as will be understood by those skilled in the art, all language, such as "up to," "at least," etc., refers to a range that is inclusive of the recited numbers and can then be divided into subranges as discussed above. Finally, as will be understood by those skilled in the art, a range includes each individual member. Thus, for example, a group having 1 to 3 ingredients refers to a group having 1, 2, or 3 ingredients. Similarly, a group having 1 to 5 ingredients refers to a group having 1, 2, 3, 4, or 5, etc. ingredients.

[0135] Various of the above-described and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements may subsequently occur to those skilled in the art, each of which is also intended to be encompassed by the embodiments of the present disclosure.

Claims

1. 1. A vapor adsorption air intake comprising: an air intake defining an interior wall surface; and an adsorbent material sheet product comprising an adsorbent material sheet and at least one porous cover layer; the adsorbent material sheet product is located along and adjacent the interior wall surface for interaction with vapor; and one or more holes for attaching the adsorbent sheet to an interior wall surface of a vapor adsorbing air intake located within the periphery of the adsorbent sheet; the sheet of adsorbent material includes a first adsorbent having a first butane working capacity (BWC) and a second adsorbent having a second BWC, the first BWC being greater than the second BWC; each of the one or more holes having an edge seal; and a vapor adsorbing air intake, wherein the sheet of adsorbent material has a first population of particles having a first average particle size and a second population of particles having a second average particle size, the ratio of the first average particle size to the second average particle size being from about 1:2 to about 1:

10.

2. The vapor adsorbing air intake of claim 1 , wherein at least one of the first adsorbent material and the second adsorbent material comprises a carbonaceous material.

3. 3. The vapor adsorbing air intake of claim 2, wherein the carbonaceous material is selected from the group consisting of activated carbon, reactivated carbon, carbon nanotubes, graphene, and combinations thereof.

4. 4. The vapor adsorbing air intake of claim 3, wherein the carbonaceous material is activated or reactivated carbon.

5. The adsorbent material sheet includes at least one of a first adsorbent material, a second adsorbent material, and a binder, and the binder is selected from the group consisting of polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF), and the like. ２ or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV curable acrylate, UV curable methacrylate, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof.

6. Each of the at least one porous cover layer is made of a material selected from the group consisting of polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF), ２ or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV curable acrylate, UV curable methacrylate, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof.

7. A vapour adsorbing air intake according to any preceding claim, wherein the porous cover layer is in the form of a non-woven fabric.

8. 8. The vapor adsorption air intake of any one of claims 1 to 7, wherein the vapor adsorption air intake is at least one of an air filter box or housing, an air intake pipe, a mass airflow sensor, a throttle body, an air intake manifold, an air intake runner connected to an individual cylinder or combustion chamber, or an air intake runner connected to multiple cylinders or combustion chambers.

9. A vapor-adsorbing air intake according to any preceding claim, wherein the edge seal is further proximate to the sheet of adsorbent material.

10. 10. The vapor-adsorbing air intake of claim 9, wherein the edge seal has an edge seal width of about 1 mm to about 10 mm.

11. 10. The vapor adsorbing air intake of claim 9, wherein the edge seal has an edge seal width of about 2.5 mm to about 5 mm.

12. An adsorbent material sheet product, comprising: a vapor-adsorbing air intake section configured to attach the adsorbent sheet to an interior wall surface of the vapor-adsorbing air intake section located within a periphery of the adsorbent sheet, the adsorbent sheet having an edge seal disposed on the periphery of the adsorbent sheet and proximate to the one or more holes; the sheet of adsorbent material includes a first adsorbent having a first butane working capacity (BWC) and a second adsorbent having a second BWC, the first BWC being greater than the second BWC; and the adsorbent sheet product having a first population of particles having a first average particle size and a second population of particles having a second average particle size, the ratio of the first average particle size to the second average particle size being from about 1:2 to about 1:

10.

13. 13. The adsorbent material sheet product of claim 12, wherein the edge seal has an edge seal width of from about 1 mm to about 10 mm.

14. 13. The adsorbent material sheet product of claim 12, wherein the edge seal has an edge seal width of from about 2.5 mm to about 5 mm.

15. 1. A method of making an adsorbent material sheet product, said method comprising: mixing a binder and an adsorbent material; forming at least one sheet of adsorbent material from the mixture of said binder and said adsorbent material; providing one or more holes located within the periphery of the sheet of adsorbent material for attaching the sheet of adsorbent material to an interior wall surface of a vapor adsorbing air intake; providing a porous cover layer on said at least one sheet of adsorbent material; and forming an edge seal disposed around the periphery of the absorbent material sheet product and proximate to the one or more holes; the sheet of adsorbent material includes a first adsorbent having a first butane working capacity (BWC) and a second adsorbent having a second BWC, the first BWC being greater than the second BWC; and wherein the sheet of adsorbent material has a first population of particles having a first average particle size and a second population of particles having a second average particle size, and the ratio of the first average particle size to the second average particle size is from about 1:2 to about 1:

10.

16. 16. The method of claim 15, wherein the edge seal is formed by localized heating via infrared radiation, ultrasonic vibration, or contact with a heated tool; localized curing or localized crosslinking via ultraviolet radiation or oxidizing or free radical compounds; localized application of an adhesive, binder, pressure-sensitive adhesive, or primer; mechanical fastening via at least one of stitching, creasing, stapling, or clamping; and combinations of two or more of the foregoing processes.

17. 1. A method of capturing vapor in a vapor adsorption air intake, the method comprising: providing an air intake defining an interior wall surface and an adsorbent material sheet product located along and positioned along the interior wall surface, the adsorbent material sheet product including at least one porous cover layer; and contacting the adsorbent material sheet product, thereby allowing the vapor to be adsorbed by the adsorbent material sheet product; the sheet of adsorbent material includes a first adsorbent having a first butane working capacity (BWC) and a second adsorbent having a second BWC, the first BWC being greater than the second BWC; the sheet of adsorbent material having one or more holes configured to attach the sheet of adsorbent material to an interior wall surface of a vapor adsorption air intake located within the periphery of the sheet of adsorbent material; each of the one or more holes having an edge seal; and wherein the sheet of adsorbent material has a first population of particles having a first average particle size and a second population of particles having a second average particle size, and the ratio of the first average particle size to the second average particle size is from about 1:2 to about 1:

10.

18. 18. The method of claim 17, further comprising desorbing the vapors previously adsorbed by the adsorbent sheet product by contacting the adsorbent sheet product with a purge gas.

19. 1. A vapor adsorption air intake comprising: an air intake defining an interior wall surface; 1. An adsorbent sheet comprising an adsorbent material and a binder, the binder being selected from the group consisting of polytetrafluoroethylene (PTFE or TEFLON), polyvinylidene fluoride (PVF), ２ or PVDF), ethylene-propylene-diene (EPDM) rubber, polyethylene oxide (PEO), UV curable acrylate, UV curable methacrylate, thermoset divinyl ether, polybutylene terephthalate, acetal or polyoxymethylene resin, fluoroelastomer, perfluoroelastomer (FFKM) and / or tetrafluoroethylene / propylene rubber (FEPM), aramid polymer, para-aramid polymer, meta-aramid polymer, polytrimethylene terephthalate, ethylene acrylic elastomer, polyimide, polyamide-imide, polyurethane, low and high density polyethylene, polypropylene, biaxially oriented polypropylene (BoPP), polyethylene terephthalate (PET), biaxially oriented polyethylene terephthalate (BoPET), polychloroprene, or copolymers or combinations thereof; the adsorbent material sheet is located along and adjacent the interior wall surface for interaction with vapor; the sheet of adsorbent material includes a first adsorbent having a first butane working capacity (BWC) and a second adsorbent having a second BWC, the first BWC being greater than the second BWC; the sheet of adsorbent material having one or more holes positioned within a periphery of the sheet of adsorbent material configured for attaching the sheet of adsorbent material to the interior wall surface; each of the one or more holes having an edge seal; a vapor adsorbing air intake, wherein the sheet of adsorbent material has a first population of particles having a first average particle size and a second population of particles having a second average particle size, the ratio of the first average particle size to the second average particle size being from about 1:2 to about 1:10.

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