Evaporative Emissions Canister With Liquid-Fuel-Resistant Adsorbent Beds

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Solution Overview

Problem

Evaporative emissions canisters face challenges with liquid fuel contamination, leading to reduced capacity, damage, and potential failure due to the accumulation of heavy hydrocarbons and liquid fuel intrusion, which is exacerbated by the use of renewable fuels and space constraints in vehicle fuel systems.

Innovation Solution

Incorporation of a first adsorbent material resistant to liquid fuel, positioned adjacent to the inlet, which acts as a protective barrier, preventing liquid fuel from reaching the second adsorbent material and maintaining the integrity of the canister.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high-capacity adsorbents are used at the charge side to maximize hydrocarbon capture, then the canister capacity is improved, but the adsorbent is more susceptible to damage from liquid fuel and heavy compound accumulation

Engineering Contradiction:

Improvehydrocarbon capture capacityVSAvoidadsorbent resistance to liquid fuel damage

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The adsorbent bed is segmented into multiple zones with different characteristics. The charge side uses high-capacity adsorbent for maximum hydrocarbon capture, while the vent side uses lower-capacity, liquid-fuel-resistant adsorbent to protect against liquid fuel damage. This segmentation allows each zone to perform its specific function optimally without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the adsorbent bed are assigned different qualities based on their functional requirements. The charge side region uses high-capacity adsorbent optimized for hydrocarbon capture, while the vent side region uses liquid-fuel-resistant adsorbent optimized for durability. This local differentiation resolves the contradiction between capacity and reliability.

Inventive Principle:

Principle #3Local quality

2Quantity of substance

If the canister is exposed to liquid fuel containing oxygenates and additives, then liquid fuel may be adsorbed in the carbon adsorbent, but this significantly reduces the storage capacity and can damage the adsorbent pellets

Engineering Contradiction:

Improvestorage capacityVSAvoidliquid fuel contamination damage

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The vent side adsorbent acts as an intermediary protective layer between the liquid fuel and the high-capacity charge side adsorbent. This intermediary layer adsorbs the harmful liquid fuel components first, preventing them from reaching and damaging the main storage capacity region, thus protecting the overall system while maintaining storage capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The vent side uses lower-capacity, liquid-fuel-resistant adsorbent that can tolerate exposure to liquid fuel without damage. This sacrificial layer is designed to handle the liquid fuel contamination burden, protecting the more valuable high-capacity adsorbent in the charge side from degradation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If liquid fuel enters the canister and adsorbent pellets are broken, then the canister may capture hydrocarbons, but air flow restriction increases significantly leading to catastrophic failure

Engineering Contradiction:

Improvehydrocarbon captureVSAvoidair flow restriction

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The vent side adsorbent bed serves as a cushioning protective layer that absorbs the impact and harmful effects of liquid fuel before it reaches the charge side adsorbent. This beforehand protection prevents pellet breakage in the main storage region, thereby preventing the catastrophic air flow restriction that would result from broken pellets.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 prevents damage to the canister by adsorbing liquid fuel, maintaining the canister's functionality and compliance with emission standards, while reducing the risk of flow restriction and failure.

Implementation Method 1

a bed of a first adsorbent material adjacent the inlet, and a bed of a second adsorbent material separated from the inlet by the bed of the first adsorbent material

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS12523190B2Evaporative emissions canister with liquid-fuel-resistant adsorbent

Publication Date: 2026.01.13 PHINIA JERSEY HOLDINGS LLC

AI summary

An evaporative emissions (fuel vapor) canister is provided. The canister includes a casing defining an internal volume therein, and the casing includes an inlet in fluid communication with the internal volume. The internal volume includes a bed of a first adsorbent material adjacent the inlet, and a bed of a second adsorbent material separated from the inlet by the bed of the first adsorbent material. The first adsorbent material is resistant to liquid fuel, and the second adsorbent material is different than the first adsorbent material. Liquid fuel that enters the internal volume of the casing via the inlet is adsorbed by the first adsorbent material such that the first adsorbent material protects the second adsorbent material from the liquid fuel. The first adsorbent material is thereby protected from damage by the liquid fuel. A method of making an evaporative emissions canister is also provided.