Activated Carbon Sorbent Laminate for Compact Vapor Capture
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Solution Overview
Problem
Existing Onboard Refueling Vapor Recovery systems for vehicles are heavy, bulky, and difficult to manufacture, necessitating improved technologies for hydrocarbon removal from vehicle emissions.
Innovation Solution
Development of vapor adsorbing devices comprising dried slurry layers with sorbent materials like activated carbon and permeable layers, utilizing binders and adhesive layers for construction, and optionally including cover and intermediate layers for enhanced hydrocarbon capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional Onboard Refueling Vapor Recovery systems are used, then hydrocarbon recovery function is achieved, but the system becomes heavy and bulky
Solution Approach 1:
The patent employs porous sorbent materials (such as activated carbon, zeolites, or silica gel) as the core component of the vapor recovery system. These porous materials provide high surface area for adsorption, enabling effective hydrocarbon vapor capture in a compact, lightweight form factor, thus resolving the contradiction between recovery efficiency and system weight
Solution Approach 2:
The patent utilizes composite material structures combining sorbent materials with binder materials and permeable support layers. This composite approach optimizes both the adsorption performance and mechanical integrity while maintaining lightweight characteristics, addressing the contradiction between functional efficiency and weight
2Quantity of substance
If traditional Onboard Refueling Vapor Recovery systems are used, then hydrocarbon recovery function is achieved, but the system becomes difficult to manufacture
Solution Approach 1:
The patent divides the vapor recovery system into distinct functional layers: sorbent material layer, binder layer, and permeable support layer. This segmentation allows each component to be manufactured and quality-tested separately, then assembled through lamination, significantly improving ease of manufacture while maintaining hydrocarbon recovery efficiency
Solution Approach 2:
The patent prepares slurries of sorbent materials and binders in advance before the lamination process. This preliminary preparation of materials in slurry form facilitates uniform application and consistent quality during manufacturing, reducing production complexity and improving ease of manufacture
3Volume of moving object
If compact vapor adsorbing devices are developed, then device size is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional layers (sorbent, binder, permeable support) into a single integrated laminate structure. This merging of functions into unified layers reduces the overall device volume while the standardized lamination process keeps manufacturing complexity manageable, resolving the contradiction between compactness and complexity
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 devices provide efficient and compact hydrocarbon capture, addressing the limitations of existing systems while meeting EPA emission standards.
Implementation Method 1
one or more dried slurry layers comprising a sorbent material
Data Source
AI summary
Sorbent materials for the adsorption of hydrocarbons and methods for manufacturing them are described. The sorbents include a slurry of activated carbon and a porous sheet layer permeable to hydrocarbons configured to remove emissions from air intakes. The methods for manufacturing the sorbent materials include providing both a hydrocarbon permeable layer and a slurry that includes the sorbent material, drying the slurry, and affixing the dried slurry layer to the surface of the hydrocarbon permeable layer.