Segmented Carbon Monolith in Foam Encapsulation

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Solution Overview

Problem

Existing hydrocarbon-trapping devices in air induction systems face issues such as breakage due to vibration, risk of carbon monolith pieces being drawn into the engine, and reduced efficiency when the adsorbing element becomes saturated, which limits their effectiveness in reducing hydrocarbon emissions.

Innovation Solution

A hydrocarbon adsorption assembly featuring a carbon-based media encapsulated in open cell or reticulated foam layers, designed to be securely positioned within an air filter housing with attachment features for easy replacement, maximizing hydrocarbon adsorption while minimizing damage and maintaining airflow efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hydrocarbon-trapping device is positioned in the air induction system, then hydrocarbon adsorption is improved, but the device is susceptible to breakage due to vibration or engine backfire

Engineering Contradiction:

Improvehydrocarbon adsorption effectivenessVSAvoiddevice durability

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The carbon monolith is divided into multiple smaller cylindrical elements (e.g., 10-50 pieces) rather than using a single large monolith. This segmentation reduces the risk that a single point of failure will compromise the entire device and prevents large broken pieces from being drawn into the engine, thus resolving the contradiction between maintaining adsorption effectiveness and improving durability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The carbon monolith pieces are enclosed within a flexible mesh envelope (such as wire mesh or metal screen) that allows the structure to flex and deform under vibration or backfire pressure without breaking. This flexible containment protects the carbon elements while maintaining their adsorption function, addressing both reliability and strength concerns

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If the adsorbing element is made larger to maximize hydrocarbon adsorption, then adsorption capacity is improved, but the risk of breakage and carbon pieces entering the engine increases

Engineering Contradiction:

Improvehydrocarbon adsorption capacityVSAvoidrisk of carbon pieces entering engine

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By dividing the total carbon adsorption capacity into multiple small cylindrical elements, the design maintains high adsorption capacity while ensuring that individual elements are too small to cause engine damage if broken. The segmented structure allows the system to achieve the required adsorption capacity without the hazards associated with large monolithic structures

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A mesh envelope acts as an intermediary structure that contains the carbon monolith pieces. This intermediate layer prevents direct contact between broken carbon pieces and the engine while still allowing hydrocarbon gases to pass through and be adsorbed, thus resolving the contradiction between adsorption capacity and prevention of harmful particles entering the engine

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If the hydrocarbon-trapping device is made more robust to prevent breakage, then device durability is improved, but access for replacement becomes more difficult

Engineering Contradiction:

Improvedevice durabilityVSAvoidaccessibility for replacement

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The modular segmented design allows the hydrocarbon trapping device to be divided into replaceable components. When the carbon monolith becomes saturated or damaged, individual segments or the entire assembly can be easily removed and replaced without requiring complex disassembly, thus maintaining durability while improving ease of replacement

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design facilitates easy replacement of the carbon monolith elements when they become saturated with hydrocarbons. The segmented structure and mesh containment allow for quick removal and disposal of spent carbon elements and installation of fresh ones, maintaining high durability through easy maintenance rather than through overly robust permanent construction

Inventive Principle:

Principle #34Discarding and recovering

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively traps hydrocarbons, filters carbon dust, and facilitates easy replacement, enhancing the durability and efficiency of hydrocarbon adsorption while maintaining airflow, thus addressing the limitations of existing devices.

Implementation Method 1

a carbon based media disposed in the first encapsulating layer

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

at least one of the first encapsulating layer and the second encapsulating layer is formed from at least one of an open cell foam and a reticulated foam

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS7763104B2Hydrocarbon trap assembly

Publication Date: 2010.07.27 HANON SYST CO LTD

AI summary

A hydrocarbon adsorption assembly is shown, wherein the hydrocarbon adsorption assembly is disposed in an encapsulating layer adapted to be received by an air filter of an automobile.