Not applicable.
This disclosure relates generally to canisters that adsorb and desorb fuel vapors generated in fuel systems of engines installed in a vehicle or the like.
U.S. Pat. No. 8,177,894 (B2), which is also published as Japanese Laid-Open Patent Publication No. 2010-007573, discloses a canister. This canister includes a case having a fluid channel formed therein, adsorption chambers containing adsorbent disposed in the fluid channel, and filters disposed within corresponding adsorption chambers to extend across an end portions of the corresponding adsorption chambers in a direction orthogonal to a flow direction of the fluid. The peripheral edge of each filter is fusion-bonded to the corresponding filter supporting portion about the entire filter supporting portion.
According to the above-described publication, “a ring weld projection” used to fuse the filter to the filter supporting portion of the case is required to be disposed about the entire filter supporting portion. This makes the structure (i.e., the configuration) of the case complex. Additionally, by virtue of the long fusion length, the associated fusion costs increase. It is notable that the fusion cost also includes expenses required for the amount of fusion energy, consumables, equipment, tools, and the like.
In one embodiment described herein, a canister includes a case having a fluid channel formed therein. In addition, the canister includes an adsorption chamber disposed in the fluid channel and containing an adsorbent. Further, a filter is disposed within the adsorption chamber and extending across an end portion of the adsorption chamber in a direction orthogonal to a flow direction of a fluid. The case also includes a filter supporting portion facing the outer peripheral edge of the filter. The filter supporting portion includes a plurality of fused portions to which the peripheral edge of the filter are fusion-bonded and a plurality of non-fused portions to which the peripheral edge of the filter are not fusion-bonded. The plurality of fused portions and the plurality of non-fused portions are arranged in an alternating manner about a lengthwise direction of the filter supporting portion.
With this configuration, protrusions used for fusion, which are to be used to fuse-bond the filter to the filter supporting portion of the case, are not required to be disposed about the entire filter supporting portion, and may instead be disposed intermittently in the lengthwise direction of the filter supporting portion. Hence, a simplified case configuration may be achieved. Additionally, fusion length may be shortened, and in this manner fusion cost may be reduced.
A fusion length corresponding to a total length of the plurality of fused portions (e.g., sum of the lengths) may be within a range from 15% to 60% of the entire length about the filter supporting portion.
With this structural configuration, the load necessary for the fused portions may be ensured and fusion cost may be reduced.
The structure including the plurality of fused portions and the plurality of non-fused portions may include at least one corner. The at least one corner has a width measured in a direction that is orthogonal to the flow direction of the fluid and that intersects with the lengthwise direction of the filter supporting portion. At least one of the plurality of fused portions may be disposed on the at least one corner.
With this configuration, the filter may be prevented from being rolled up in the proximity of the at least one corner.
As previously described, the long fusion length required to wholly fuse the filter to the filter supporting portion of the case in many conventional canisters is relatively complex and expensive. Accordingly, embodiments described herein are directed to canisters that offer the potential for a simplified case configuration with lower fusion costs.
One embodiment in accordance with principles described herein will now be described with reference to the drawings. For convenience of explanation, a canister configuration will be briefly described first, followed by a description of the configuration of an attached filter. For convenience in describing relative orientations, an up-to-down direction (Z-direction) and a left-to-right direction (X-direction) are defined and used hereinafter on the basis of the orientation of the canister illustrated in
An overview of the canister structure will now be described. As illustrated in
As shown in
As shown in
As shown in
A gas-permeable buffer plate 30 is horizontally positioned inside the second adsorption chamber 18 in a vertically-movable manner, and serves to vertically partition the adsorbent granules 273, which are filled throughout the adsorption chamber 18, into upper and lower portions. Also, the gas-permeable push plates 311 and 313 are each horizontally arranged to cover a corresponding opening at the top of the one of the both adsorption chambers 17 and 18, respectively, in a vertically movable manner. A spring 321 comprising a coil spring is vertically interposed between the push plate 311 and the cover plate 14 (above the push plate 311 and below the cover plate 14), thereby biasing the push plate 311 downward in an elastic manner. Similarly, a spring 323 comprising a coil spring is vertically interposed between the push plate 313 and the cover plate 14 (above the push plate and below the cover plate), thereby biasing the push plate 313 downward in an elastic manner. Adsorption chambers 17 and 18 communicate with each other through a vertical gap between the cover plate 14 and the first partitioning wall 20 (above said first partitioning wall 20 and below the cover plate 14). With this structural configuration, an inverted U-shaped fluid channel 33 is formed within the case 12. A fluid (e.g., gas containing fuel vapor) flows through the fluid channel 33. In other words, within both adsorption chambers 17 and 18, the fluid flows in the up-to-down direction (the Z-direction). The fluid channel 33 is a channel allowing the tank port 23 and the purge port 24 at the bottom of the first adsorption chamber 17 to communicate with the atmospheric port 25 at the bottom of the second adsorption chamber 18 in an indirect manner. Additionally, filters 341 and 343 in the form of gas permeable sheets are disposed on either side of the first partitioning wall 20: vertically between the push plate 311 in the first adsorption chamber 17 and the adsorbent granules 271 (below the push plate 311 and above the adsorbent granules 271); and vertically between the push plate 313 in the second adsorption chamber 18 and the adsorbent granules 273 (below the push plate 313 and above the adsorbent granules 273), respectively. The filters 341 and 343 may be formed of urethane foam or the like.
Filters 281, 282, and 283 will now be described. As shown in
As shown in
The bottom wall 16 includes a filter supporting portion 383 that is situated inside the second adsorption chamber 18 and is formed by a part of the upper surface of the bottom wall 16, in particular, a radially outer peripheral portion of the upper surface of the bottom wall 16. The filter supporting portion 383 forms a planar surface extending in an X-Y plane, which is a plane orthogonal to the up-to-down vertical direction (the Z-direction). The bottom wall 16 also includes a stepped face 403 situated radially inward of the filter supporting portion 383. The stepped face 403 and the filter supporting portion 383 collectively form a stepped structure with several steps in the vertical direction. The stepped face 403 is orthogonal to the Z-direction (that is the stepped face 403 extends within the X-Y plane) and has a planar face in an X-Y plane situated radially inward of, and at a lower level than, the filter supporting portion 383 (
As illustrated in
As illustrated in
It is preferable that a total length of the first protrusions 423 (e.g., sum of the lengths of all the first protrusions 423) is set within a range from 15% to 60% of the entire length of the filter supporting portion 383. This means that it is preferable that the ratio of a total length of the first protrusions 423 (e.g., sum of the lengths of all the first protrusions 423) to the total length of the filter supporting portion 383 is set within a range from 15% to 60%.
Within the second adsorption chamber 18, a lower end portion of each of left and right inner faces of the surrounding wall 36 includes a pair of second protrusions 443 in the radially inward direction (
As illustrated in
Next, the installation of the filter 283 in the case body 13 will be described. The filter 283 is fitted within the second adsorption chamber 18 horizontally in the X-Y plane, with no substantial gap in the X, Y, or Z directions between the filter supporting portion 383 and the filter 283. That is, the filter 283 is installed in the second adsorption chamber 18 so as to be orthogonal to the flow direction of the fluid. If the installation process is performed by an automated assembly line, the filter 283 is moved vertically downward from above the second adsorption chamber 18 while maintaining a horizontal orientation in the X-Y plane, and while being sucked to an suction disc of a suction device (not shown) utilizing a negative pressure; and is thereby set on the filter supporting portion 383, which is on the bottom wall 16 and includes the first protrusions 423. At this time, portions of the outer radial peripheral edge of the filter 283 elastically contact the second protrusions 443 by utilizing the elasticity of the filter 283. By this contact, the filter 283 is temporarily fixed to the case body 13. Negative pressure applied to the filter 283 by the suction device is then released and the suction disc is discharged out of the second adsorption chamber 18.
Subsequently, ultrasonic vibration is applied to a welding horn of an ultrasonic welding device (not shown) while the welding horn is pressed against a portion of the filter 283. By using the welding horn in this manner, the first protrusions 423 and the outer radial arc portions of the filter 283, each oppositely facing the corresponding first protrusion 423, are melted and bonded (i.e., fusion-bonded) to each other. It is notable that each protrusion 423 is fusion-bonded with the filter 283 via at least a portion of the protrusion 423 including the vertex of the triangular cross-section thereof. Portions of the filter supporting portion 383 to which portions of filter 283 are respectively fusion-bonded will be hereinafter referred to as fused portions 463 (see
The welding horn is allowed to transmit vibrations to the first protrusions 423 and is not allowed to transmit vibrations to portions of the filter supporting portion 383 with no first protrusion 423. Thus, each of the portions of filter 283, which face the corresponding portion of the filter supporting portion 383 with no first protrusion 423, is laid over the corresponding portion of the filter supporting portion 383 and is not fused to be bonded to said portion. Each of the portions of the filter supporting portion 383 to which a portion of the filter 283 is not fusion-bonded is referred to as a non-fused portion 483 (
The filter supporting portion 383 includes four fused portions 463 and four non-fused portions 483 disposed in an alternating manner along the lengthwise direction of the filter supporting portion 383 (
After application of ultrasonic vibration is stopped, the welding horn is discharged out of the second adsorption chamber 18. Filters 281 and 282 are attached to the compartments 17A and 17B, respectively, of the first adsorption chamber 17 (
In this manner, the filters 281, 282, and 283 are attached to the case body 13. After these filters are attached, the respective adsorption chambers 17 and 18 of the case body 13 are filled with the adsorbent granules 271 and 273. Subsequently, the buffer plate 30, the push plates 311 and 313, springs 321 and 323, and filters 341 and 343, etc. are attached to the canister, followed by closing the opening at the top of the case body 13 with the cover plate 14. The canister 10 is thus finished (see
According to the above-described canister 10, after the fusing process takes place, the filter supporting portion 38 of the case 12 includes the fused portions 46, to which portions of the filter 28 are fusion-bonded, and the non-fused portions 48 to which the peripheral edge of the filter are not fusion-bonded, where fusion-bonded and non-fused portions of the filter 28 are placed in an alternating manner about the filter supporting portion 38 in the lengthwise direction of the filter supporting portion 38. Accordingly, the first protrusions 42 for fusing portions of the filter 28 on the filter supporting portion 38 are not required to be formed about the entire filter supporting portion 38, and may instead be formed intermittently in the lengthwise direction of the filter supporting portion 38, thereby simplifying the configuration of the case 12. Further, in this manner, the fusion length can be shortened and fusion cost can be reduced, wherein said design is applied to compartments 17A and 17B of the first adsorption chamber, as well as the second adsorption chamber 18.
Further the structure including the fused portions 46 and non-fused portions 48 within each of the compartments 17A and 17B of the first adsorption chamber 17, as well as the second adsorption chamber 18, includes the four corners that each have a width measured in an X-Y plane (e.g., a plane oriented perpendicular to the Z-direction) generally perpendicular to the central axis of the corresponding compartment 17A, 17B or adsorption chamber 18 and that intersects with the lengthwise direction of the filter supporting portions 38. In other words, a width of each corner is measured perpendicular to the lengthwise direction of the filter supporting portion 38. The fused portions 46 are disposed on the four corners of each of the filter supporting portions 38. With this configuration, corner portions of the filter 28 may be prevented from being rolled up at the four protruding portions.
The present disclosure is not intended to be limited to the above-described embodiment and the above embodiment may be modified in various ways. For example, a structure including a plurality of fused portions 46 and non-fused portions 48 is not limited to a rectangular structure and may be another polygonal structure such as a triangular or hexagonal structure. In this context, the term “polygonal structure” includes a structure that is obtained by rounding corners of a polygonal structure. Additionally, a structure may be a sector-shaped structure or a structure having at least one corner having a width measured in an X-Y plane (e.g., a plane oriented perpendicular to the Z-direction) and that intersects with the lengthwise direction of the structure. In case of a structure having at least one corner, it is only necessary that the fused portion(s) 46 is disposed on the at least one corner. A structure including a plurality of fused portions 46 and non-fused portions 48 may have a circular, semi-circular, or elliptic shape. Several pairs of the fused portions 46 each may be disposed in an alternating manner with a tiny gap therebetween to extend along the structure. The various examples described above in detail with reference to the attached drawings are intended to be representative and thus not limiting. The detailed description is intended to teach a person of skill in the art to make, use and/or practice various aspects of the present teachings and thus is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be applied and/or used separately or with other features and teachings to provide improved canisters, and/or methods of making and using the same. Moreover, the various combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught to describe representative examples of the invention. Further, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. All features disclosed in the description and/or the claims are intended to be disclosed as informational, instructive and/or representative and may thus be construed separately and independently from each other. In addition, all value ranges and/or indications of groups of entities are also intended to include possible intermediate values and/or intermediate entities for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.
Number | Date | Country | Kind |
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2017-239340 | Dec 2017 | JP | national |
This application is a continuation of U.S. patent application Ser. No. 16/220,071 filed on Dec. 14, 2018, and entitled “Canister,” which claims benefit of Japanese Patent Application Serial No. 2017-239340 filed on Dec. 14, 2017, and entitled “Canister,” each of which is hereby incorporated by reference in its entirety for all purposes.
Number | Date | Country | |
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Parent | 16220071 | Dec 2018 | US |
Child | 17476715 | US |