Sorbent Material Sheets for Fuel Tank Vapor Recovery
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Solution Overview
Problem
Conventional Onboard Refueling Vapor Recovery (ORVR) systems are bulky, heavy, and costly due to the use of loose adsorbent particles, which complicates manufacturing, maintenance, and disposal, and fail to meet stringent emissions regulations, particularly in reducing minute 'bleed' emissions.
Innovation Solution
The use of sorbent material sheets with high adsorption capacity, composed of activated carbon and a binder, which are either housed or directly integrated into the fuel tank, offering improved performance and reduced weight and size while maintaining high adsorption efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If loose adsorbent particles are used in conventional ORVR canisters, then the system can capture fuel vapors, but the canisters become bulky, heavy, and complex to manufacture and maintain
Solution Approach 1:
The patent uses flexible sorbent sheets instead of loose particles, which can be contained in lighter, simpler housings or directly integrated into the fuel tank, reducing canister weight and complexity while maintaining vapor adsorption functionality
Solution Approach 2:
The patent integrates the sorbent material directly into the fuel tank structure, merging the vapor recovery function with the existing tank, thereby eliminating the need for separate heavy canisters and reducing overall system weight
2Reliability
If loose adsorbent particles are used in conventional ORVR canisters, then the system can capture fuel vapors, but the device complexity and cost increase
Solution Approach 1:
The flexible sorbent sheets simplify the canister structure by eliminating the need for complex internal support structures required to contain loose particles, reducing manufacturing complexity and cost
Solution Approach 2:
By integrating the sorbent into the fuel tank, the patent reduces the number of separate components and assembly steps, thereby simplifying the overall device structure and reducing manufacturing complexity
3Object-generated harmful factors
If conventional ORVR systems are designed to meet stringent emissions regulations, then vapor emissions are reduced, but the canisters require higher adsorbent capacity which increases size and weight
Solution Approach 1:
The flexible sorbent sheets can be configured to maximize surface area within the fuel tank, providing high adsorption capacity in a compact form factor that does not increase canister volume
Solution Approach 2:
The sorbent material integrated into the fuel tank serves multiple functions: it captures vapors during refueling, stores them during normal operation, and releases them during engine operation, providing high capacity without requiring additional volume
4Object-generated harmful factors
If conventional ORVR systems are designed to meet stringent emissions regulations, then vapor emissions are reduced, but the manufacturing and disposal becomes more cumbersome
Solution Approach 1:
The flexible sorbent sheets are easier to manufacture and install than rigid canisters with loose particles, as they can be directly integrated into the fuel tank during manufacturing, simplifying the production process
Solution Approach 2:
By integrating the sorbent into the fuel tank, the patent combines manufacturing steps and reduces the number of separate components that need to be manufactured, assembled, and disposed of, thereby improving ease of manufacture and disposal
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 sorbent material sheets provide enhanced pollution control, reducing the size, weight, and cost of ORVR systems while meeting stringent emissions targets by increasing the adsorption capacity and reducing 'bleed' emissions, allowing for more efficient vapor recovery and combustion.
Implementation Method 1
excess vapor is captured and adsorbed within a chemical canister
Implementation Method 2
the Engine Control Unit (ECU) permits adsorbed vapors to be released from the canister and into the engine fuel system
Data Source
AI summary
Sorbent material sheets provide for enhanced performance in vapor adsorbing applications over conventional canisters and other emissions control equipment. The sorbent material sheets can be formed as part of a small, lightweight canister, or can be integrated into a fuel tank. The sorbent material sheets can also be used as part of an onboard refueling vapor recovery system to control volatile organic compound emissions from fuel tanks of gasoline vehicles, such as automobiles.