Polymer Honeycomb Carbon Filter with Plasma-Deposited Adsorption Layer

Solution Overview

Problem

Existing carbon canisters for vehicular evaporative emission control face challenges with fragile and costly activated carbon honeycomb structures, which fail to meet increasingly stringent emission regulations effectively.

Innovation Solution

A carbon filter with a polymer-based body and case, featuring a carbon-black adsorption layer with diamond-like properties deposited via plasma-enhanced chemical vapor deposition, incorporating nickel, silver, copper, or graphite particles, and a honeycomb structure for enhanced adsorption capacity and durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If activated carbon honeycomb structures are used to supplement adsorption capacity, then evaporative emission control effectiveness is improved, but the structure becomes fragile and costly

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a composite structure combining a polymer-based monolithic body with a carbon-black adsorption layer deposited on its surface. This composite approach provides both the structural strength of polymer materials and the adsorption capacity of carbon materials, resolving the contradiction between reliability and strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The monolithic body incorporates a honeycomb structure with numerous internal passages that provide high surface area for adsorption. This porous configuration delivers effective evaporative emission control while maintaining structural integrity through the monolithic design, avoiding the fragility of traditional honeycomb structures.

Inventive Principle:

Principle #31Porous materials

2Reliability

If activated carbon honeycomb structures are used to supplement adsorption capacity, then evaporative emission control effectiveness is improved, but manufacturing cost increases

Engineering Contradiction:

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical assembly of separate carbon honeycomb elements with a monolithic body formed by injection molding. The adsorption layer is applied through plasma-enhanced chemical vapor deposition, substituting complex mechanical construction with more efficient manufacturing processes that reduce cost and improve consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the physical state and application method of the carbon adsorption material, transitioning from pre-formed carbon honeycomb structures to a deposited carbon-black layer. This parameter change enables more cost-effective manufacturing through standard injection molding and surface deposition techniques.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If a polymer-based monolithic body with carbon-black adsorption layer is used, then manufacturing cost and flexibility are improved, but adsorption capacity must be maintained

Engineering Contradiction:

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies the carbon-black adsorption layer specifically on the internal surfaces of the honeycomb passages where gas flow occurs. This localized application ensures adsorption capacity is concentrated where needed, maintaining effectiveness while using material efficiently for cost-effective manufacturing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The honeycomb structure provides high surface area through its porous configuration, and the carbon-black layer coating these surfaces delivers adequate adsorption capacity. The combination of porous geometry with surface coating maintains reliability while enabling simpler, more flexible manufacturing.

Inventive Principle:

Principle #31Porous materials

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 provides improved adsorption efficiency and durability, reducing hydrocarbon emissions while controlling costs and enhancing manufacturing flexibility, thus meeting stricter emission regulations.

Implementation Method 1

the adsorption layer is disposed along the surfaces of the bleed passages with a plasma-enhanced chemical vapor deposition process and has diamond-like properties

Methodology Applied

Scientific EffectPlasma-enhanced chemical vapor deposition: Plasma Enhanced Chemical Vapour Deposition

Implementation Method 2

an adsorption layer is disposed along surfaces of the bleed passages, and the adsorption layer is a carbon-black material

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS11673089B2Active carbon filter for a carbon canister and a method for producing the same

Publication Date: 2023.06.13

AI summary

A method for producing an active carbon filter for a carbon canister includes forming a body having a honeycomb structure with a plurality of bleed passages from a polymer based material, and forming an adsorption layer along a surface of the body, where the adsorption layer is made of a carbon based material.