Multi-Layer Hydrocarbon Trap for Universal Vehicle Packaging
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Solution Overview
Problem
Existing hydrocarbon traps for air induction systems in vehicles require unique designs for each application, making them difficult to scale and package due to space and material constraints, and lack a universal design that can leverage economies of scale and reduce engineering and manufacturing costs.
Innovation Solution
A multiple layer hydrocarbon trap design featuring a plurality of generally flat layers of adsorbing material secured together by grommets or adhesives, allowing for a modular and flexible solution that can be adapted to various applications, with a universal design that reduces material waste and facilitates competitive bidding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a unique design is used for each application, then the hydrocarbon trap can be optimized for specific performance requirements, but the engineering and development resources increase and economies of scale cannot be leveraged
Solution Approach 1:
The patent applies universality by designing a standardized hydrocarbon trap configuration with adjustable parameters (number of layers, layer dimensions, grommet positions) that can serve multiple applications. The same basic design structure with 2-6 layers of adsorbing material secured by grommets can be adapted to different vehicle types and emission requirements, eliminating the need for unique designs for each application while maintaining performance optimization through parameter adjustment.
2Reliability
If traditional hydrocarbon trap designs are used, then they can provide emission control, but they are difficult to scale and package within a vehicle due to space limitations and size constraints
Solution Approach 1:
The patent applies segmentation by dividing the hydrocarbon trap into multiple discrete layers of adsorbing material (2-6 layers) that are secured together by grommets. This layered structure allows the trap to be scaled in small increments based on emission requirements while maintaining a compact form factor. The segmented design also enables flexible packaging within vehicle space constraints, as the thin layers can be stacked efficiently.
Solution Approach 2:
The patent transitions from traditional three-dimensional bulky trap designs to a multi-layer thin-film structure. By stacking multiple thin layers of adsorbing material (each layer being relatively flat and thin) rather than using a single thick structure, the design achieves the required adsorption capacity in a much thinner profile, enabling efficient packaging within vehicle constraints.
3Reliability
If more absorber channel openings are used, then vapor adsorption capacity increases, but the material constraints and space requirements increase
Solution Approach 1:
The patent applies partial action by using a limited number of layers (2-6 layers) of adsorbing material rather than attempting to provide full adsorption capacity in a single thick layer. This partial approach through multiple thin layers achieves sufficient adsorption capacity for most applications while using less total material, and the number of layers can be adjusted based on specific emission requirements.
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 multiple layer hydrocarbon trap design enables efficient adaptation to multiple applications, reduces engineering and manufacturing costs, and minimizes material waste, while providing a cost-effective solution for reducing hydrocarbon emissions by using a universal design that can be easily assembled and scaled.
Implementation Method 1
some vehicles include a hydrocarbon trap in the AIS having one or more hydrocarbon adsorbing surfaces to adsorb vaporized hydrocarbons during engine off soaks
Implementation Method 2
The bypass hydrocarbon trap may include multiple layers of generally flat sheets of hydrocarbon adsorbing material that are mechanically secured together by multiple mechanical fasteners, such as multiple grommets
Data Source
AI summary
An air induction system for an engine includes an air filter box configured to receive an air filter that separates the air filter box into an atmosphere side and a filtered air side, a clean-air duct coupled downstream from the air filter box and upstream of the engine relative to a direction of air flow during engine operation, a flow-through hydrocarbon trap positioned within the clean-air duct, and a bypass hydrocarbon trap secured within the air filter box on the filtered air side, the hydrocarbon trap having a plurality of generally flat or coiled layers of hydrocarbon adsorbing material sandwiched together and secured one to another. Mechanical fasteners such as grommets may extend through the plurality of layers to secure the layers together. The fasteners may be secured to ribs extending along an upper surface of the air filter box or an interior surface of the clean-air duct.