US20160059468A1 - Engine Air Intake Duct with Molded-In Hydrocarbon Vapor Trap - Google Patents
Engine Air Intake Duct with Molded-In Hydrocarbon Vapor Trap Download PDFInfo
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- US20160059468A1 US20160059468A1 US14/471,172 US201414471172A US2016059468A1 US 20160059468 A1 US20160059468 A1 US 20160059468A1 US 201414471172 A US201414471172 A US 201414471172A US 2016059468 A1 US2016059468 A1 US 2016059468A1
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- hydrocarbon
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
- B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
- B01D53/0407—Constructional details of adsorbing systems
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M33/00—Other apparatus for treating combustion-air, fuel or fuel-air mixture
- F02M33/02—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel
- F02M33/04—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel returning to the intake passage
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M33/00—Other apparatus for treating combustion-air, fuel or fuel-air mixture
- F02M33/02—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel
- F02M33/04—Other apparatus for treating combustion-air, fuel or fuel-air mixture for collecting and returning condensed fuel returning to the intake passage
- F02M33/043—Coating of the intake passage with a porous material
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/02—Air cleaners
- F02M35/0218—Air cleaners acting by absorption or adsorption; trapping or removing vapours or liquids, e.g. originating from fuel
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/10—Air intakes; Induction systems
- F02M35/10242—Devices or means connected to or integrated into air intakes; Air intakes combined with other engine or vehicle parts
- F02M35/10281—Means to remove, re-atomise or redistribute condensed fuel; Means to avoid fuel particles from separating from the mixture
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/10—Air intakes; Induction systems
- F02M35/10314—Materials for intake systems
- F02M35/10321—Plastics; Composites; Rubbers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M35/00—Combustion-air cleaners, air intakes, intake silencers, or induction systems specially adapted for, or arranged on, internal-combustion engines
- F02M35/10—Air intakes; Induction systems
- F02M35/10314—Materials for intake systems
- F02M35/10334—Foams; Fabrics; Porous media; Laminates; Ceramics; Coatings
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D2253/10—Inorganic adsorbents
- B01D2253/102—Carbon
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- B01D2253/108—Zeolites
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- B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
- B01D2257/702—Hydrocarbons
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- B01D2258/06—Polluted air
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2008—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2008—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article
- B29C2049/2013—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements inside the article for connecting opposite walls, e.g. baffles in a fuel tank
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2021—Inserts characterised by the material or type
- B29C2049/2047—Tubular inserts, e.g. tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2073—Means for feeding the inserts into the mould, preform or parison, e.g. grippers
- B29C2049/2078—Means for feeding the inserts into the mould, preform or parison, e.g. grippers being retractable during or after blow moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
- B29C2049/2086—Means for verifying or keeping the position of the insert, e.g. sensors, or attachment on mould wall
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/58—Blowing means
- B29C49/60—Blow-needles
- B29C2049/609—Two or more blow-needles
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
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- B29K2633/00—Use of polymers of unsaturated acids or derivatives thereof for preformed parts, e.g. for inserts
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- B29L2031/749—Motors
- B29L2031/7492—Intake manifold
Definitions
- the present disclosure relates to an intake duct for an internal combustion engine and to a method for molding such a duct to include a hydrocarbon vapor trap.
- Hydrocarbon (HC) vapor traps are used in the air induction path of internal combustion engines to capture hydrocarbon vapors emanating from within the engine, fuel system, pollution control system, and/or related components, and which would otherwise escape into the environment.
- the HC vapor trap is therefore part of a vehicle's pollution control system, reducing potentially undesired evaporative fuel emissions.
- a HC vapor trap includes, as its operative component, an element that adsorbs HC vapors present in an air intake duct and which contact the element. It is known to form an HC-adsorbing element from one or more sheets of paper or polymeric material impregnated with a HC vapor adsorption/desorption material, such as activated carbon.
- the HC-adsorbing element is located in the engine intake duct to adsorb HC vapors that may be present when the engine is shut down.
- the HC vapors are then desorbed from the element into the intake airflow when the engine is re-started and fresh air is drawn into the air induction system.
- the desorbed vapors are carried into the engine along with the air charge and burned.
- a HC trap within/along an engine's air induction path.
- a HC trap is located downstream from an air filter box and upstream from an intake plenum and/or intake runners feeding into the cylinders of the engine.
- U.S. Pat. No. 8,191,535 owned by the owner of this Application and the disclosure of which is incorporated herein by reference, discloses a HC vapor trap comprising a tubular HC-adsorbing sleeve surrounding a plastic cage.
- the cage is inserted into the hollow interior of a first duct component through an open end thereof.
- a second duct component is fastened to the open end of the first component to enclose the trap unit and secure it in its desired installed position.
- an engine intake duct comprises a hydrocarbon-adsorbing element secured to a frame to form an insert, and a plastic shell surrounding the insert and engaging the frame to retain the insert with a surface of the insert exposed to a hollow interior of the shell.
- the shell is formed by positioning the insert in registry with a blow-molding core, placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form the shell.
- the HC-adsorbing element may be formed by thermoforming at least one sheet of polymeric material, at least a portion of the sheet impregnated with a HC vapor adsorption/desorption material.
- the HC-adsorbing element may have a depression formed in a surface thereof during the thermoforming, such that the element is secured to the frame by engagement between a tab projecting from the frame and the depression
- a method of manufacturing an engine intake duct comprises securing a hydrocarbon-adsorbing element to a frame to form an insert, positioning the insert in registry with a blow-molding core, placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form a shell engaging the frame to retain the insert with a surface of the insert exposed to a hollow interior of the shell.
- the frame comprises at least one positioning feature and the step of placing the insert in contact with the core comprises placing the positioning feature in engagement with a complementary feature of the core.
- FIG. 1 is a perspective view of an engine air intake duct with a molded-in-place hydrocarbon-adsorbing insert
- FIG. 2 is a perspective view of the intake duct of FIG. 1 from a different angle;
- FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 2 ;
- FIG. 4 is a cross-sectional view taken along line 4 - 4 of FIG. 2 ;
- FIG. 5 is a cross-sectional view taken along line 5 - 5 of FIG. 1 ;
- FIG. 6 is an plan view of a hydrocarbon trap insert
- FIG. 7 is an exploded perspective view of the insert of FIG. 6 ;
- FIG. 8 is a cross-sectional view taken along line 8 - 8 of FIG. 6 ;
- FIG. 9 is a schematic perspective view of the insert of FIGS. 5-8 in registry with a core as used in a blow molding process;
- FIG. 10 is a schematic view of a blow molding apparatus used in the molding of an intake duct of the type shown in FIGS. 1-5 ;
- FIG. 11 is a schematic view of the blow molding apparatus of FIG. 10 with the mold halves closed.
- FIGS. 1 and 2 are simplified views of an air intake duct 10 such as may be used in an air induction system of an internal combustion engine (not shown).
- intake duct 10 is designed and intended to be located at an appropriate point upstream of the engine.
- duct 10 may extend between an air cleaner box (not shown) and an intake plenum and/or throttle body (not shown).
- the upstream and downstream ends of duct 10 may be connected with the adjoining portions of the air induction system by any means known in the art.
- Duct 10 is shown to have a generally oval cross section and include an approximately 45° bend, but this geometry is exemplary in nature only. The exact dimensions and shape of the duct depends upon many variables and is mainly dictated by the available package space within the engine compartment.
- Intake duct 10 comprises a one-piece, tubular shell 12 that is formed of a plastic material by an appropriate process, such as blow-molding.
- plastic material such as blow-molding.
- the particular type and formulation of plastic used to form the shell 12 is, as will be apparent to a person skilled in the art, determined by various factors such as the particular molding process used and the required mechanical characteristics of the finished product.
- a hydrocarbon (HC) trap insert 20 is housed within shell 12 , the shell being molded around the HC trap insert such that the portion of shell overlying the HC trap insert forms an outward bulge 12 a relative to the immediately-adjacent portions of the shell.
- HC trap insert 20 fits within a receptacle 18 recessed relative to the interior surface of shell 12 , the receptacle corresponding to and formed by outward bulge 12 a .
- HC trap insert 20 is preferably fully seated into receptacle 20 so that the insert does not project (or projects only minimally) into the interior of duct 10 thereby causing little or no restriction to airflow through the duct.
- the inner surface of HC trap insert 20 is exposed to the hollow interior of the duct 10 .
- HC trap insert 20 comprises a frame 30 and a hydrocarbon-adsorbing (HCA) element 40 retained and supported by the frame.
- HCA hydrocarbon-adsorbing
- Frame 30 is preferably formed from a relatively rigid material such as plastic, and may advantageously be manufactured by injection molding.
- relatively rigid is defined as meaning that the frame 30 is able to flex or deflect as necessary to allow element 40 to be assembled with it, yet the frame retains its desired shape and supports the insert during handling, throughout the blow-molding process (to be described below), and during use in the vehicle.
- Frame 30 comprises a plurality of perimeter segments 32 and one or more inner segments 34 a , 34 b .
- a plurality of small tabs 36 extend inwardly from perimeter frame segments 32 .
- First and second retention fingers 38 a , 38 b extend outwardly from perimeter frame segments 32 in opposite circumferential directions.
- a rib 34 c is formed integrally with and extends along the length of inner frame segment 34 b.
- HCA element 40 may comprise one or more layers of polymeric sheets that are impregnated with a HC vapor adsorption/desorption material.
- the polymeric material may, for example, be non-woven polyester and the HC vapor adsorption/desorption material may be activated carbon, in some examples. Additionally, or alternatively, the HC vapor adsorption/desorption material may include carbon, activated carbon, zeolites, silicon oils, cyclodextrins, and/or any other suitable adsorption/desorption material as known in the art.
- HCA element 40 may be manufactured by a thermoforming process wherein one or more polymeric sheets are placed in a forming die (not shown) and subjected to heat and pressure.
- surface features that aid in retaining HCA element 40 in connection with frame 30 are formed in/on HCA element 40 by the forming die during the thermo-forming process.
- Such surface features may include depressions 42 along the perimeter edges of the element and elongated channels 44 a , 44 b extending along its inner/concave surface. These features cooperate with mating features of frame 30 to secure the two components together.
- HC trap insert 20 is assembled by snapping HCA element 40 into frame 30 so that tabs 36 engage the respective depressions 42 , and inner frame segments 34 a , 34 b engage the respective channels 44 a , 44 b .
- the engagement between the mating features serves to properly position and securely hold the element 40 to the frame 30 .
- Any other appropriate means/method of attaching HCA element 40 to frame 30 may be used. Such methods include welding, adhesives, and heat-staking.
- Frame 30 and HCA element 40 are curved to match the curvature of the inner surface of the shell 12 .
- HCA element 40 follows the contours of the adjacent portions of the shell interior and a maximum amount of the surface area of the element 40 is exposed to vapors and intake air present in the duct 10 .
- Shell 12 is molded over the assembled HC trap insert 20 so that the plastic material of the shell wraps around the convex outer surface of the HC trap insert and contacts perimeter frame segments 32 and retention fingers 38 a , 38 b thereby retaining the HC trap insert securely within the shell after the plastic material cools and hardens.
- HC trap insert 20 extends around approximately half of the circumference of the interior (as best seen in FIG. 3 ) and along approximately half of the overall axial length of duct 10 , but this configuration is exemplary only.
- a duct according to the present invention may have a molded-in HC trap insert that occupies the entire interior surface of the shell, or any portion thereof.
- Air intake duct 10 may advantageously be manufactured by a blow-molding process in which shell 12 is molded around/over HC trap insert 20 .
- FIG. 9 shows HC trap insert 20 positioned in registry with a blow-molding core 60 .
- Core 60 may be slightly tapered along its length (the vertical dimension as oriented in FIG. 9 ) so that HC trap insert 20 slides downwardly over the core 60 for positive positioning thereon. The taper also enables easy removal of the completed duct 10 from the mold when complete. Correct alignment of HC trap insert 20 relative to core 60 is ensured by engagement between rib 34 c and an axial groove 62 in the surface of the core as the insert slides down over the core.
- Core 60 may include one or more interior passages 64 through which positive pressure is applied during the blow-molding process, as is known in the art.
- HCA adsorbing element 40 being of such a size and configuration that it extends or wraps around somewhat less than one-half of the inner circumference of shell 12 , as best seen in FIG. 3 .
- Retention fingers 38 a , 38 b extend from the frame perimeter 32 in opposite circumferential directions to increase the overall size of HC trap insert 20 such that the insert wraps around more than one-half of the circumference of duct 10 and core 60 .
- retention fingers 38 a , 38 b retain the HC trap insert in proper registry with core 60 when the insert is placed over the core, as shown in FIG. 9 .
- Retention fingers 38 a , 38 b also increase the area of frame 30 that is contacted by shell 12 during the molding process, as best seen in FIGS. 1-5 .
- the increased contact area provides for more secure engagement between the trap element 20 and the shell 12 .
- FIGS. 10 and 11 are simplified schematic depictions of a blow-molding apparatus.
- core 60 is secured to the top of a holding fixture 70 and HC trap insert 20 is positioned in registry with the core in preparation for blow-molding.
- HC trap insert 20 is positioned in registry with the core in preparation for blow-molding.
- a parison 72 of molten plastic is extruded from a mandrel 74 and die head 76 .
- the tubular parison 72 descends (under gravity) downward between the mold halves 78 a , 78 b and surrounds the core 60 .
- the mold halves 78 a , 78 b are then closed (as seen in FIG.
- parison 72 forms the shell 12 , which is now coupled with HC trap insert 20 to form the duct 10 .
- Molding the shell 12 in one piece around HC trap insert 20 as described above enables the practical and economical production of air intake ducts with an integrated HCA element of a wide range of possible sizes, shapes, and locations within the duct.
- the trap is retained securely within the duct 10 regardless of the shape. No additional fasteners, machining, or assembly steps are required.
- the relatively flexible HCA element 40 supported by the relatively rigid frame 30 provides unique advantages.
- the relatively rigid frame 30 also allows secure and consistent placement of the insert 20 in proper registry with the core during the production process.
Abstract
Description
- The present disclosure relates to an intake duct for an internal combustion engine and to a method for molding such a duct to include a hydrocarbon vapor trap.
- Hydrocarbon (HC) vapor traps are used in the air induction path of internal combustion engines to capture hydrocarbon vapors emanating from within the engine, fuel system, pollution control system, and/or related components, and which would otherwise escape into the environment. The HC vapor trap is therefore part of a vehicle's pollution control system, reducing potentially undesired evaporative fuel emissions.
- A HC vapor trap includes, as its operative component, an element that adsorbs HC vapors present in an air intake duct and which contact the element. It is known to form an HC-adsorbing element from one or more sheets of paper or polymeric material impregnated with a HC vapor adsorption/desorption material, such as activated carbon. The HC-adsorbing element is located in the engine intake duct to adsorb HC vapors that may be present when the engine is shut down. The HC vapors are then desorbed from the element into the intake airflow when the engine is re-started and fresh air is drawn into the air induction system. The desorbed vapors are carried into the engine along with the air charge and burned.
- Numerous methods and structures have been proposed to position a HC trap within/along an engine's air induction path. In a typical installation, a HC trap is located downstream from an air filter box and upstream from an intake plenum and/or intake runners feeding into the cylinders of the engine.
- U.S. Pat. No. 8,191,535, owned by the owner of this Application and the disclosure of which is incorporated herein by reference, discloses a HC vapor trap comprising a tubular HC-adsorbing sleeve surrounding a plastic cage. During assembly of the duct, the cage is inserted into the hollow interior of a first duct component through an open end thereof. A second duct component is fastened to the open end of the first component to enclose the trap unit and secure it in its desired installed position.
- In an embodiment disclosed herein, an engine intake duct comprises a hydrocarbon-adsorbing element secured to a frame to form an insert, and a plastic shell surrounding the insert and engaging the frame to retain the insert with a surface of the insert exposed to a hollow interior of the shell. The shell is formed by positioning the insert in registry with a blow-molding core, placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form the shell.
- The HC-adsorbing element may be formed by thermoforming at least one sheet of polymeric material, at least a portion of the sheet impregnated with a HC vapor adsorption/desorption material. The HC-adsorbing element may have a depression formed in a surface thereof during the thermoforming, such that the element is secured to the frame by engagement between a tab projecting from the frame and the depression
- In another embodiment disclosed herein, a method of manufacturing an engine intake duct comprises securing a hydrocarbon-adsorbing element to a frame to form an insert, positioning the insert in registry with a blow-molding core, placing a molten plastic parison and mold around the insert and core, and blow-molding the parison to form a shell engaging the frame to retain the insert with a surface of the insert exposed to a hollow interior of the shell.
- In another embodiment, the frame comprises at least one positioning feature and the step of placing the insert in contact with the core comprises placing the positioning feature in engagement with a complementary feature of the core.
-
FIG. 1 is a perspective view of an engine air intake duct with a molded-in-place hydrocarbon-adsorbing insert; -
FIG. 2 is a perspective view of the intake duct ofFIG. 1 from a different angle; -
FIG. 3 is a cross-sectional view taken along line 3-3 ofFIG. 2 ; -
FIG. 4 is a cross-sectional view taken along line 4-4 ofFIG. 2 ; -
FIG. 5 is a cross-sectional view taken along line 5-5 ofFIG. 1 ; -
FIG. 6 is an plan view of a hydrocarbon trap insert; -
FIG. 7 is an exploded perspective view of the insert ofFIG. 6 ; -
FIG. 8 is a cross-sectional view taken along line 8-8 ofFIG. 6 ; -
FIG. 9 is a schematic perspective view of the insert ofFIGS. 5-8 in registry with a core as used in a blow molding process; -
FIG. 10 is a schematic view of a blow molding apparatus used in the molding of an intake duct of the type shown inFIGS. 1-5 ; and -
FIG. 11 is a schematic view of the blow molding apparatus ofFIG. 10 with the mold halves closed. - As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
-
FIGS. 1 and 2 are simplified views of anair intake duct 10 such as may be used in an air induction system of an internal combustion engine (not shown). As is well known in the art,intake duct 10 is designed and intended to be located at an appropriate point upstream of the engine. For example,duct 10 may extend between an air cleaner box (not shown) and an intake plenum and/or throttle body (not shown). The upstream and downstream ends ofduct 10 may be connected with the adjoining portions of the air induction system by any means known in the art.Duct 10 is shown to have a generally oval cross section and include an approximately 45° bend, but this geometry is exemplary in nature only. The exact dimensions and shape of the duct depends upon many variables and is mainly dictated by the available package space within the engine compartment. -
Intake duct 10 comprises a one-piece,tubular shell 12 that is formed of a plastic material by an appropriate process, such as blow-molding. The particular type and formulation of plastic used to form theshell 12 is, as will be apparent to a person skilled in the art, determined by various factors such as the particular molding process used and the required mechanical characteristics of the finished product. A hydrocarbon (HC)trap insert 20 is housed withinshell 12, the shell being molded around the HC trap insert such that the portion of shell overlying the HC trap insert forms anoutward bulge 12 a relative to the immediately-adjacent portions of the shell. - As best seen in
FIGS. 3-5 , HC trap insert 20 fits within areceptacle 18 recessed relative to the interior surface ofshell 12, the receptacle corresponding to and formed by outwardbulge 12 a.HC trap insert 20 is preferably fully seated intoreceptacle 20 so that the insert does not project (or projects only minimally) into the interior ofduct 10 thereby causing little or no restriction to airflow through the duct. The inner surface ofHC trap insert 20 is exposed to the hollow interior of theduct 10. - As best seen in
FIGS. 6-8 ,HC trap insert 20 comprises aframe 30 and a hydrocarbon-adsorbing (HCA)element 40 retained and supported by the frame. -
Frame 30 is preferably formed from a relatively rigid material such as plastic, and may advantageously be manufactured by injection molding. The term “relatively rigid” is defined as meaning that theframe 30 is able to flex or deflect as necessary to allowelement 40 to be assembled with it, yet the frame retains its desired shape and supports the insert during handling, throughout the blow-molding process (to be described below), and during use in the vehicle. -
Frame 30 comprises a plurality ofperimeter segments 32 and one or moreinner segments small tabs 36 extend inwardly fromperimeter frame segments 32. First andsecond retention fingers perimeter frame segments 32 in opposite circumferential directions. Arib 34 c is formed integrally with and extends along the length ofinner frame segment 34 b. -
HCA element 40 may comprise one or more layers of polymeric sheets that are impregnated with a HC vapor adsorption/desorption material. The polymeric material may, for example, be non-woven polyester and the HC vapor adsorption/desorption material may be activated carbon, in some examples. Additionally, or alternatively, the HC vapor adsorption/desorption material may include carbon, activated carbon, zeolites, silicon oils, cyclodextrins, and/or any other suitable adsorption/desorption material as known in the art. -
HCA element 40 may be manufactured by a thermoforming process wherein one or more polymeric sheets are placed in a forming die (not shown) and subjected to heat and pressure. In the disclosed embodiment, surface features that aid in retainingHCA element 40 in connection withframe 30 are formed in/onHCA element 40 by the forming die during the thermo-forming process. Such surface features may includedepressions 42 along the perimeter edges of the element andelongated channels frame 30 to secure the two components together. -
HC trap insert 20 is assembled by snappingHCA element 40 intoframe 30 so thattabs 36 engage therespective depressions 42, andinner frame segments respective channels element 40 to theframe 30. Any other appropriate means/method of attachingHCA element 40 to frame 30 may be used. Such methods include welding, adhesives, and heat-staking. -
Frame 30 andHCA element 40 are curved to match the curvature of the inner surface of theshell 12. WhenHC trap insert 20 is operatively positioned insideshell 12,HCA element 40 follows the contours of the adjacent portions of the shell interior and a maximum amount of the surface area of theelement 40 is exposed to vapors and intake air present in theduct 10.Shell 12 is molded over the assembled HC trap insert 20 so that the plastic material of the shell wraps around the convex outer surface of the HC trap insert and contactsperimeter frame segments 32 andretention fingers - The dimensions and shape of an HC trap insert designed for use in a particular air duct will be tailored to that specific application and depend upon design requirement such as: the required adsorption capacity of the
HCA element 40; the size, shape, and location of theduct 10; and other packaging constraints. In the depicted embodiment,HC trap insert 20 extends around approximately half of the circumference of the interior (as best seen inFIG. 3 ) and along approximately half of the overall axial length ofduct 10, but this configuration is exemplary only. A duct according to the present invention may have a molded-in HC trap insert that occupies the entire interior surface of the shell, or any portion thereof. -
Air intake duct 10 may advantageously be manufactured by a blow-molding process in which shell 12 is molded around/overHC trap insert 20.FIG. 9 shows HC trap insert 20 positioned in registry with a blow-molding core 60.Core 60 may be slightly tapered along its length (the vertical dimension as oriented inFIG. 9 ) so that HC trap insert 20 slides downwardly over thecore 60 for positive positioning thereon. The taper also enables easy removal of the completedduct 10 from the mold when complete. Correct alignment of HC trap insert 20 relative tocore 60 is ensured by engagement betweenrib 34 c and anaxial groove 62 in the surface of the core as the insert slides down over the core.Core 60 may include one or moreinterior passages 64 through which positive pressure is applied during the blow-molding process, as is known in the art. - In the embodiment of an air intake duct depicted herein, design requirements have resulted in
HCA adsorbing element 40 being of such a size and configuration that it extends or wraps around somewhat less than one-half of the inner circumference ofshell 12, as best seen inFIG. 3 .Retention fingers frame perimeter 32 in opposite circumferential directions to increase the overall size of HC trap insert 20 such that the insert wraps around more than one-half of the circumference ofduct 10 andcore 60. By providing this “wrap-around” geometry ofHC trap insert 20,retention fingers core 60 when the insert is placed over the core, as shown inFIG. 9 . -
Retention fingers frame 30 that is contacted byshell 12 during the molding process, as best seen inFIGS. 1-5 . The increased contact area provides for more secure engagement between thetrap element 20 and theshell 12. -
FIGS. 10 and 11 are simplified schematic depictions of a blow-molding apparatus. InFIG. 10 ,core 60 is secured to the top of a holdingfixture 70 andHC trap insert 20 is positioned in registry with the core in preparation for blow-molding. In the blow-molding process, as is well known in the art, aparison 72 of molten plastic is extruded from amandrel 74 and diehead 76. Thetubular parison 72 descends (under gravity) downward between the mold halves 78 a, 78 b and surrounds thecore 60. The mold halves 78 a, 78 b are then closed (as seen inFIG. 11 ), forming the molten parison over theHC trap insert 20 andcore 60. Air (or other gas) is then injected under pressure into the mold through blow pins 80, 82 to urge the still-soft plastic of the parison outwardly against the inner surfaces of the mold dies abovecore 60. Upon cooling,parison 72 forms theshell 12, which is now coupled with HC trap insert 20 to form theduct 10. - Molding the
shell 12 in one piece around HC trap insert 20 as described above enables the practical and economical production of air intake ducts with an integrated HCA element of a wide range of possible sizes, shapes, and locations within the duct. The trap is retained securely within theduct 10 regardless of the shape. No additional fasteners, machining, or assembly steps are required. - To achieve good results in the blow-molding process described herein, it has been found that having the relatively
flexible HCA element 40 supported by the relativelyrigid frame 30 provides unique advantages. The relativelyrigid frame 30 also allows secure and consistent placement of theinsert 20 in proper registry with the core during the production process. - While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
Claims (14)
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US14/471,172 US9278475B1 (en) | 2014-08-28 | 2014-08-28 | Engine air intake duct with molded-in hydrocarbon vapor trap |
CN201510537017.5A CN105386907B (en) | 2014-08-28 | 2015-08-27 | Engine intake manifold with molded hydrocarbon vapor trap |
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US14/471,172 US9278475B1 (en) | 2014-08-28 | 2014-08-28 | Engine air intake duct with molded-in hydrocarbon vapor trap |
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US20220018318A1 (en) * | 2020-07-17 | 2022-01-20 | Ford Global Technologies, Llc | Tamper resistant hydrocarbon trap for combustion engines |
US11635049B1 (en) * | 2021-12-20 | 2023-04-25 | Mann+Hummel Gmbh | Air induction system including air duct having cylindrical wall with opening extending radially therethrough and feature for minimizing airflow disturbances caused by presence of opening |
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US9840987B2 (en) * | 2015-05-08 | 2017-12-12 | Mann+Hummel Gmbh | Air induction duct with integrated hydrocarbon adsorber |
US10876667B2 (en) * | 2016-08-10 | 2020-12-29 | Ford Motor Company | Method of making an inline housing for a part enclosed in a tube |
JP6880965B2 (en) * | 2017-04-18 | 2021-06-02 | トヨタ紡織株式会社 | Internal combustion engine inlet duct |
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US20200010039A1 (en) * | 2018-07-03 | 2020-01-09 | Inoac Corporation | Duct |
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US20220018318A1 (en) * | 2020-07-17 | 2022-01-20 | Ford Global Technologies, Llc | Tamper resistant hydrocarbon trap for combustion engines |
US11506158B2 (en) * | 2020-07-17 | 2022-11-22 | Ford Global Technologies, Llc | Tamper resistant hydrocarbon trap for combustion engines |
US11635049B1 (en) * | 2021-12-20 | 2023-04-25 | Mann+Hummel Gmbh | Air induction system including air duct having cylindrical wall with opening extending radially therethrough and feature for minimizing airflow disturbances caused by presence of opening |
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US9278475B1 (en) | 2016-03-08 |
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