Canister

Abstract

Provided is a canister that includes a first adsorbing layer K1 including a first adsorbing material Q1 as an adsorbing material Q and a second adsorbing layer K2 including, as the adsorbing material Q, a second adsorbing material Q2 different from the first adsorbing material Q1. The first absorbing layer K1 and the second absorbing layer K2 are provided inside a casing 10. In a flowing direction of fuel vapor J between one end and another end of the casing 10, the first adsorbing layer K1 is disposed at a position in contact with an air port 10a at the other end, and the second adsorbing layer K2 is disposed closer to the one end than the first adsorbing layer K1 is. The first adsorbing material Q1 adsorbs the fuel vapor J at an adsorbing rate that is lower than an adsorbing rate of the second adsorbing material Q2.

Claims

1. A canister comprising: a casing internally provided with an adsorbing layer that comprises an adsorbing material capable of adsorbing and desorbing fuel vapor; a tank port provided at one end of the casing and configured to allow the fuel vapor to flow into the casing; a purge port provided at the one end of the casing and configured to allow the fuel vapor to flow out of the casing; an air port provided at another end of the casing and configured to allow air to flow into and out of the casing; a first adsorbing layer provided inside the casing, and comprising a first adsorbing material as the adsorbing material, wherein the first absorbing layer is disposed at a position in contact with the air port at the other end in a flowing direction of the fuel vapor between the one end and the other end; and a second adsorbing layer that is provided inside the casing, and comprising a second adsorbing material different from the first adsorbing material, and wherein the second absorbing material is disposed closer to the one end than the first adsorbing layer is in the flowing direction, and wherein the first adsorbing material adsorbs the fuel vapor at an adsorbing rate that is lower than an adsorbing rate of the second adsorbing material.

2. The canister according to claim 1, wherein the first adsorbing material has an equilibrium adsorption capacity with respect to the fuel vapor that is smaller than an equilibrium adsorption capacity of the second adsorbing material with respect to the fuel vapor.

3. The canister according to claim 1, wherein the first adsorbing material has an average particle diameter that is larger than an average particle diameter of the second adsorbing material.

4. The canister according to claim 1, wherein: the first adsorbing layer and the second adsorbing layer comprise a heat storage material comprising a phase change material that absorbs and releases latent heat according to a temperature change, the heat storage material has an average particle diameter of 0.9 mm or more and 1.6 mm or less, and the adsorbing material is activated carbon having a particle size distribution in which particles having a particle size of 0.71 mm or more and 2.36 mm or less constitute 95 wt % or more.

5. The canister according to claim 4, wherein the average particle diameter of the heat storage material is 0.6 times or more and 1.3 times or less of an average particle diameter of the adsorbing material.

6. The canister according to claim 4, wherein the first adsorbing layer has a content rate of the heat storage material that is higher than a content rate of the heat storage material in the second adsorbing layer.

7. The canister according to claim 4, wherein the first adsorbing layer and the second adsorbing layer comprise a heat storage material comprising a phase change material that absorbs and releases latent heat according to a temperature change, and wherein the heat storage material in the second adsorbing layer has a melting point that is lower than a melting point of the heat storage material in the first adsorbing layer.

8. The canister according to claim 4, wherein the heat storage material in the first adsorbing layer has a melting point of 36° C. or higher, and the heat storage material in the second adsorbing layer has a melting point lower than 36° C.

9. The canister according to claim 4, wherein: the first adsorbing layer and the second adsorbing layer comprise a molded heat storage material molded from microcapsules in which a phase change material that absorbs and releases latent heat according to a temperature change is encapsulated, the molded heat storage material has a columnar shape and has a first end surface on a first side of a column axis of the molded heat storage material and a second end surface on a second side of the column axis as viewed in a direction orthogonal to the column axis, and an average value of R.sub.1/rand R.sub.2/r is 0.57 or more, where R.sub.1 represents a length of a curved surface of a first edge portion, which connects the first end surface and a circumferential side surface around the column axis, in a radial direction of the first end surface, R.sub.2 represents a length of a curved surface of a second edge portion, which connects the second end surface and the circumferential side surface, in a radial direction of the second end surface, and r represents a radius of a cross section of the molded heat storage material taken along the direction orthogonal to the column axis.

10. The canister according to claim 4, wherein the heat storage material has a latent heat of 150 J/g or more and 200 J/g or less.

11. The canister according to claim 4, wherein the heat storage material has a bulk density of 0.40 g/mL or more and 0.60 g/mL or less.

12. The canister according to claim 4, wherein a mass ratio of the heat storage material to the first adsorbing material in the first adsorbing layer is 0.15 or more and 0.80 or less, and a mass ratio of the heat storage material to the second adsorbing material in the second adsorbing layer is 0.05 or more and 0.50 or less.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 is a schematic configuration diagram of an automotive vehicle including a canister according to an embodiment.

[0049] FIG. 2 is a conceptual diagram showing a function of the canister according to an embodiment.

[0050] FIG. 3 is a schematic configuration diagram of a heat storage material according to an embodiment.

DESCRIPTION OF THE INVENTION

[0051] A canister according to an embodiment of the present invention can suppress fluctuation of the concentration of transpired gas in purge gas during desorbing operation and improve controllability of purging while maintaining economic efficiency.

[0052] The following describes the canister with reference to the drawings.

[0053] As shown in FIG. 1, a canister 100 according to the present embodiment includes a casing 10 that is internally provided with an adsorbing layer K capable of adsorbing fuel vapor J, and the canister 100 can be suitably applied to a commonly-known automotive vehicle. The automotive vehicle according to the present embodiment includes: a fuel tank 12 for storing fuel such as gasoline; the canister 100 configured to adsorb fuel vapor J vaporized in the fuel tank 12 particularly during fuel supply (during ORVR) and introduce the adsorbed fuel vapor J into an engine 11; and the engine 11 configured to obtain shaft output by combusting fuel including the fuel vapor J introduced from the canister 100 and combustion air in a combustion chamber (not shown).

[0054] As shown in FIG. 1, the canister 100 includes: the casing 10; a tank port 10c that communicates with the fuel tank 12 and is configured to receive fuel vapor J from the fuel tank 12; a purge port 10b configured to send fuel vapor J desorbed in the canister 100 during desorbing operation to the engine 11; and an air port 10a that communicates with ambient air. The tank port 10c and the purge port 10b are provided at one end in a flowing direction X, and the air port 10a is provided at another end in the flowing direction X. The purge port 10b communicates with the engine 11 via a purge flow path 11a. The engine 11 and the fuel tank 12 communicate with each other via a connecting path 13a.

[0055] The adsorbing layer K contains an adsorbing material Q that adsorbs and desorbs the fuel vapor J and a molded heat storage material T that is molded from microcapsules in which a phase change material that absorbs and releases latent heat according to temperature is encapsulated.

[0056] As shown in FIG. 1, the adsorbing layer K includes: a first adsorbing layer K1 that includes a first adsorbing material Q1 as the adsorbing material Q and is in contact with the air port 10a at the other end in the flowing direction X of purge gas PJ between the one end and the other end; and a second adsorbing layer K2 that includes a second adsorbing material Q2 as the adsorbing material Q different from the first adsorbing material Q1 and that is on the one end side relative to the first adsorbing layer K1. Note that in the present embodiment, the second adsorbing layer K2 is in contact with the purge port 10b and the tank port 10c at the one end, and the first adsorbing layer K1 and the second adsorbing layer K2 are separated by a predetermined separation film or the like.

[0057] Here, the first adsorbing material Q1 has a lower adsorbing rate with respect to the fuel vapor J than the second adsorbing material Q2.

[0058] The molded heat storage material T is obtained by molding a heat storage material together with a binder into granules, for example. The heat storage material is obtained by encapsulating a phase change material that absorbs and releases latent heat according to a temperature change in microcapsules. It is possible to use a known heat storage material in the form of microcapsules such as that disclosed in JP 2001-145832A or and JP 2003-311118A.

[0059] The phase change material is constituted by an organic compound and an inorganic compound having a melting point of 10° C. or higher and 80° C. or lower, for example, and examples of the phase change material include: linear aliphatic hydrocarbons such as tetradecane, pentadecane, hexadecane, heptadecane, octadecane, nonadecane, eicosane, henicosane, and docosane; natural wax; petroleum wax; hydrated inorganic compounds such as LiNO.sub.3.3H.sub.2, Na.sub.2SO.sub.4.10H.sub.2O, and Na.sub.2HPO.sub.4.12H.sub.2O; fatty acids such as capric acid and lauric acid; higher alcohols having 12 to 15 carbon atoms; and esters such as methyl palmitate and methyl stearate. Two or more compounds selected from the above-listed compounds may be used together as the phase change material.

[0060] Microcapsules that are formed by using any of these compounds as a core material through a known method such as a coacervation method or an in-situ method (interfacial reaction method) can be used. A known material such as melamine, gelatin, or glass can be used to form outer shells of the microcapsules. The heat storage material in the form of microcapsules preferably has a particle diameter of about several micrometers to several tens of micrometers. If the microcapsules are too small, the proportion of the outer shells constituting the capsules increases, and the proportion of the phase change material that repeatedly melts and solidifies relatively decreases, and therefore, the amount of heat stored per unit volume of the powdery heat storage material decreases. On the other hand, if the microcapsules are too large, the capsules need to have certain strength, and accordingly, the proportion of the outer shells constituting the capsules increases, and the amount heat stored per unit volume of the powdery heat storage material decreases.

[0061] The powdery heat storage material is molded together with a binder into a substantially cylindrical shape to obtain a granular molded heat storage material T. Various binders can be used, but a thermosetting resin such as a phenol resin or an acrylic resin is preferably used from the viewpoint of thermal stability, stability against a solvent, and strength, which are required when the binder is used in the canister. The granular molded heat storage material T is mixed with the adsorbing material Q, which also has a granular shape, and the mixture is used to obtain a heat storing effect.

[0062] The molded heat storage material T preferably has a latent heat of 150 J/g or more and 200 J/g or less.

[0063] Various known adsorbing materials can be used as the adsorbing material Q. For example, activated carbon can be used as the adsorbing material Q. Granules individually molded or crushed to have predetermined dimensions can be used as the adsorbing material Q.

[0064] On the other hand, the molded heat storage material T that is molded into a columnar shape through extrusion molding as described above as shown in FIG. 3, for example, has a first end surface M2 on a first side of a column axis P2 and a second end surface M3 on a second side of the column axis P2 as viewed in a direction orthogonal to the column axis P2, and an average value of R.sub.1/rand R.sub.2/r is 0.57 or more, where R.sub.1 represents the length of a curved surface of a first edge portion M2a, which connects the first end surface M2 and a circumferential side surface M1 around the column axis P2, in a radial direction of the first end surface M2, R.sub.2 represents the length of a curved surface of a second edge portion M3a, which connects the second end surface M3 and the circumferential side surface M1, in a radial direction of the second end surface M3, and r represents the radius of a cross section of the molded heat storage material T taken along the direction orthogonal to the column axis P2.

[0065] By adopting such a shape having rounded corners, it is possible to improve miscibility with the adsorbing material Q (dispersibility of the molded heat storage material T in the adsorbing material Q).

[0066] Note that the molded heat storage material T is shaped in such a manner that the length of the molded heat storage material T along the column axis P2 and the diameter of the cross section orthogonal to the column axis P2 do not differ very much from each other.

[0067] The molded heat storage material T and the granular adsorbing material Q preferably have the same size as far as possible or have approximately the same size in order to suppress separation of the molded heat storage material T and the adsorbing material Q from each other with the passage of time and appropriately secure a gas flow path.

[0068] However, the first adsorbing material Q1 preferably has an average particle diameter that is larger than an average particle diameter of the second adsorbing material Q2. Furthermore, the molded heat storage material T preferably has an average particle diameter (diameter 2r of the cross section orthogonal to the column axis P2 of the columnar shape shown in FIG. 3) of 0.9 mm or more and 1.6 mm or less, and the adsorbing material Q preferably has an average particle diameter of 1.0 mm or more and 1.8 mm or less. Furthermore, both the first adsorbing material Q1 and the second adsorbing material Q2 used as the adsorbing material Q are preferably activated carbon having a particle size distribution in which particles having a particle size of 0.71 mm or more and 2.36 mm or less constitute 95 wt % or more.

[0069] Also, the average particle diameter (2r in FIG. 3) of the molded heat storage material T is preferably 0.6 times or more and 1.3 times or less of the average particle diameter of the adsorbing material Q.

[0070] Also, the first adsorbing material Q1 preferably has an equilibrium adsorption capacity with respect to the fuel vapor J that is smaller than an equilibrium adsorption capacity of the second adsorbing material Q2 with respect to the fuel vapor J, and the first adsorbing layer K1 preferably has a content rate of the molded heat storage material T that is higher than a content rate of the molded heat storage material T in the second adsorbing layer K2.

[0071] The molded heat storage material T preferably has a bulk density of 0.4 g/mL or more and 0.6 g/mL or less. The adsorbing material Q desirably has a bulk density that is 0.2 times or more and 1.1 times or less of the bulk density of the molded heat storage material T, preferably 0.3 times or more and equal to or less than the bulk density of the molded heat storage material T, and more preferably 0.4 times or more and 0.9 times or less of the bulk density of the molded heat storage material T. If the bulk density of the adsorbing material Q largely differs from the bulk density of the molded heat storage material T, the adsorbing material Q or the molded heat storage material T that is heavier than the other moves downward within the casing when the canister is mounted in a vehicle or the like and vibration is applied to the canister, and separation of the adsorbing material Q and the molded heat storage material T progresses.

[0072] Furthermore, it is preferable that a mass ratio of the molded heat storage material T to the first adsorbing material Q1 in the first adsorbing layer K1 is 0.15 or more and 0.80 or less and a mass ratio of the molded heat storage material T to the second adsorbing material Q2 in the second adsorbing layer K2 is 0.05 or more and 0.50 or less. By adopting this configuration in which the mass ratio of the molded heat storage material T to the adsorbing material Q is higher in the first adsorbing layer K1 than in the second adsorbing layer K2, it is possible to suppress a temperature increase on the side of the canister that is close to ambient air and at which the temperature is likely to increase during fuel supply (ORVR) and thus prevent a reduction in adsorptivity.

[0073] Moreover, since the content rate of the molded heat storage material T is high in the first adsorbing layer K1 that is on the upstream side (the other end side of the casing), the content of the first adsorbing material Q1 can be relatively reduced in the first adsorbing layer K1 in the vicinity of the air port 10a to reduce the adsorption amount in the vicinity of the air port 10a, and consequently, it is possible to reduce the amount of fuel vapor J leaking to the outside due to a temperature difference between the inside and the outside while the vehicle is parked for a long time, and DBL (Diurnal Breathing Loss) performance can be improved.

[0074] Additionally, the molded heat storage material T included in the second adsorbing layer K2 preferably has a melting point that is lower than a melting point of the molded heat storage material T included in the first adsorbing layer K1, and it is preferable that the melting point of the molded heat storage material T included in the first adsorbing layer K1 is 36° C. or higher and the melting point of the molded heat storage material T included in the second adsorbing layer K2 is lower than 36° C. According to this configuration, in particular, the melting point of the molded heat storage material T included in the second adsorbing layer K2 on the downstream side in the flowing direction X of purge gas PJ during purging is as low as less than 36° C., and accordingly, it is possible to suppress cooling in the second adsorbing layer K2 whose temperature is likely to decrease, and consequently it is possible to effectively suppress a reduction in the concentration of transpired gas in the purge gas particularly in a later stage of purging.

[0075] As shown in FIG. 1, the casing 10 of the canister 100 preferably has dimensions and a shape designed such that a ratio L/D is 2.5 or less, where L represents the length of the adsorbing layer in the flowing direction X of purge gas PJ (including fuel vapor J) in the casing 10, and D represents the diameter of a cross section of the casing 10, which is taken along a direction orthogonal to the flowing direction X of the purge gas PJ and assumed to be a perfect circle. With this configuration, it is possible to suppress a pressure loss to a certain level or less even when the adsorbing material Q and the molded heat storage material T have small average particle diameters.

OTHER EMBODIMENTS

[0076] (1) In the above embodiment, the canister 100 is intended to be used during fuel supply (ORVR), but the canister 100 can be used not only during fuel supply but also while the vehicle is parked, stopped, or traveling.

[0077] (2) In the above embodiment, a configuration example is described in which the adsorbing layer K includes the first adsorbing layer K1 and the second adsorbing layer K2, but the adsorbing layer K may further include an adsorbing layer other than the first adsorbing layer K1 and the second adsorbing layer K2.

[0078] Also, a configuration example is described in which the first adsorbing layer K1 and the second adsorbing layer K2 are separated from each other by the separation film, but a configuration is also possible in which the separation film is not provided.

[0079] Furthermore, a configuration is also possible in which the adsorbing material Q is provided between the first adsorbing layer K1 and the second adsorbing layer K2 in such a manner that the adsorbing rate increases toward the second adsorbing layer K2.

[0080] (3) In the above embodiment, the average particle diameter of the first adsorbing material Q1 is larger than the average particle diameter of the second adsorbing material Q2.

[0081] However, the average particle diameter of the first adsorbing material Q1 may be approximate or equal to, or smaller than the average particle diameter of the second adsorbing material Q2 as long as the first adsorbing material Q1 adsorbs the fuel vapor J at a lower adsorbing rate than the second adsorbing material Q2.

[0082] Also, instead of adopting the configuration in which the average particle diameter of the first adsorbing material Q1 is larger than the average particle diameter of the second adsorbing material Q2, it is possible to adopt a configuration in which the first adsorbing material Q1 has a larger specific surface area than the second adsorbing material Q2.

[0083] (4) In the above embodiment, a configuration is described in which the adsorbing layer K includes the molded heat storage material T, but a configuration is also possible in which the molded heat storage material T is not provided. Also, the molded heat storage material T may have various shapes such as a rectangular tube-like shape, other than the cylindrical shape.

[0084] (5) In the above embodiment, the equilibrium adsorption capacity of the first adsorbing material Q1 with respect to the fuel vapor J is smaller than the equilibrium adsorption capacity of the second adsorbing material Q2 with respect to the fuel vapor J.

[0085] However, the equilibrium adsorption capacity of the first adsorbing material Q1 with respect to the fuel vapor J may be approximate or equal to, or larger than the equilibrium adsorption capacity of the second adsorbing material Q2 with respect to the fuel vapor J as long as the first adsorbing material Q1 adsorbs the fuel vapor J at a lower adsorbing rate than the second adsorbing material Q2.

[0086] (6) In the above embodiment, the content rate of the molded heat storage material T in the first adsorbing layer K1 is higher than the content rate of the molded heat storage material T in the second adsorbing layer K2.

[0087] However, the content rate of the molded heat storage material T in the first adsorbing layer K1 may be equal to or lower than the content rate of the molded heat storage material T in the second adsorbing layer K2.

[0088] Note that the configurations disclosed in the above embodiment (including the other embodiments, the same applies hereinafter) can be applied in combination with configurations disclosed in other embodiments as long as no contradiction arises. Also, the embodiments disclosed in the present specification are examples, and embodiments of the present invention are not limited to the disclosed embodiments, and it is possible to modify the embodiments as appropriate within a scope not departing from the object of the present invention.

[0089] The canister according to the present invention can be effectively used as a canister that can suppress fluctuation of the concentration of transpired gas in purge gas during desorbing operation and improve controllability of purging while maintaining economic efficiency.

DESCRIPTION OF REFERENCE SIGNS

[0090] 10 Casing [0091] 10a Air port [0092] 10b Purge port [0093] 10c Tank port [0094] 100 Canister [0095] J Fuel vapor [0096] K Adsorbing layer [0097] K1 First adsorbing layer [0098] K2 Second adsorbing layer [0099] M1 Circumferential side surface [0100] M2 First end surface [0101] M3 Second end surface [0102] M2a First edge portion [0103] M3a Second edge portion [0104] P2 Column axis [0105] PJ Purge gas [0106] Q Adsorbing material [0107] Q1 First adsorbing material [0108] Q2 Second adsorbing material [0109] T Molded heat storage material [0110] X Flowing direction