WO2015057954A1

WO2015057954A1 - Airbox with integrated evaporative emissions control

Info

Publication number: WO2015057954A1
Application number: PCT/US2014/060883
Authority: WO
Inventors: Erik Buell; Aaron BRECHBILL; Dane HOECHST
Original assignee: Erik Buell Racing, Llc
Priority date: 2013-10-16
Filing date: 2014-10-16
Publication date: 2015-04-23

Abstract

Presently disclosed is a motorcycle having an airbox having a molded housing, the airbox forming an intake air system for an internal combustion engine, and an evaporative emissions control system provided within the airbox, the evaporative emissions control system including a fuel vapor capture media disposed within a compartment defined by the molded housing of the airbox. In embodiments, the evaporative emissions control system is engaged with a housing of the airbox. In an embodiment, the evaporative emissions control system is contained within the airbox housing.

Description

AIRBOX WITH INTEGRATED EVAPORATIVE EMISSIONS CONTROL

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 61/891,612, filed October 16, 2013 the disclosure of which is incorporated here by reference.

BACKGROUND AND SUMMARY

[0002] The present disclosure relates to vehicles, namely, motorized scooters, motorcycles, ATVs, trikes, other two-wheeled motorized vehicles, other three-wheeled motorized vehicles, and vehicles having four or more wheels. More specifically the present disclosure relates to evaporative emissions control on vehicles.

[0003] Evaporative emissions control systems have been used to reduce non-exhaust hydrocarbon emissions in motor vehicles. Evaporative emissions control systems typically consist of a plastic canister containing the relevant apparatus to remove evaporated fuel vapors and allow purified air to be returned to the atmosphere. Evaporative emissions control system canisters are typically remotely mounted to the vehicle chassis and is operationally connected to the fuel tank and, optionally, other vehicle components with one or more hoses. Finding a mounting spot for a evaporative emissions control system and routing connecting hoses has been difficult, especially on two or three wheeled vehicles. Further remotely mounted evaporative emissions control system can be unattractive. Therefore, there remains a need for improved apparatuses and methods for engagement of an evaporative emissions control system with a motor vehicle.

[0004] Presently disclosed is a system that includes an airbox and an evaporative emissions control system engaged with the airbox. In an embodiment, the airbox forms an intake air system for an internal combustion engine. The airbox has an airbox housing that defines an airbox exterior and an airbox interior, and the evaporative emissions control system is engaged with the airbox housing.

[0005] Also disclosed is a vehicle system that includes an internal combustion engine having at least one combustion chamber adapted to receive a fuel-air mixture, a fuel-air mixer fluidly communicating with each of the at least one combustion chambers and adapted to supply the fuel-air mixture to each combustion chamber, an air intake system operatively communicating with the fuel-air mixer and adapted to deliver an air or air-vapor mixture to the fuel-air mixer, where the air intake system includes an airbox having an airbox housing and an evaporative emissions control system engaged with the airbox housing.

[0006] In some embodiments, the evaporative emissions control system comprises an evaporative emissions control system housing defining an evaporative emissions control system housing interior and an evaporative emissions control system housing exterior. In some embodiments, the evaporative emissions control system housing interior is adjacent to or at least partially coincident with the airbox interior.

[0007] In some embodiments, the evaporative emissions control system housing interior is a sub-set of the airbox interior. In some embodiments, the evaporative emissions control system is contained within the airbox housing. In some embodiments, the evaporative emissions control system housing comprises a component integrally formed as part of the airbox housing. In some embodiments, the evaporative emissions control system housing is integrally molded as part of the airbox housing.

[0008] In some embodiments, a system further includes a conduit configured to fluidly communicate fuel vapor from a fuel source to the evaporative emissions control system housing interior.

[0009] In some embodiments, the evaporative emissions control system housing is elongated to define a first end portion and a second end portion spaced apart from the first end portion.

[0010] In some embodiments, the evaporative emissions control system housing comprises a first aperture proximate to the first end portion, and wherein the first aperture is adapted for communication of fuel vapor between the associated fuel source and the evaporative emissions control system housing interior.

[0011] In some embodiments, the evaporative emissions control system housing comprises a second aperture, and wherein the second aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and an outside atmosphere.

[0012] In some embodiments, the housing of the evaporative emissions control system comprises a third aperture, and wherein the third aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and the fuel-air mixer. In some embodiments, the third aperture is offset from the first aperture by a region adapted to contain a fuel vapor capture media. In some embodiments, the evaporative emissions control system housing is internally partitioned to provide an extended flow path for fuel vapor or air or both fuel vapor and air between the first aperture and the third aperture.

[0013] In some embodiments, the evaporative emissions control system contains a fuel vapor capture media adapted to absorb fuel vapor and desorb fuel vapor. In some embodiments, wherein the fuel vapor capture media is activated charcoal.

[0014] In some embodiments, the fuel-air mixer is adapted to receive fuel from a fuel source, receive air or an air-vapor mixture from the air intake system, and mix the fuel and either the air or the air-vapor mixture to create the fuel-air mixture. In some embodiments, the internal combustion engine is an Otto cycle engine or a Diesel cycle engine.

[0015] Also disclosed is a motorcycle that includes an airbox having a molded housing, the airbox forming an intake air system for an internal combustion engine, and an evaporative emissions control system provided within the airbox, the evaporative emissions control system including a fuel vapor capture media disposed within a compartment defined by the molded housing of the airbox.

[0016] In an embodiment, the motorcycle also includes a fuel source, and a conduit extending between the fuel source and the airbox, the conduit configured to fluidly communicate evaporated fuel vapor from the fuel source to the fuel vapor capture media of the evaporative emissions control system within the airbox.

[0017] In an embodiment, the motorcycle also includes a fuel-air mixer configured to form a fuel-air mixture to be delivered to an engine of the motorcycle, wherein the airbox includes an air-vapor output configured to deliver an air-vapor mixture from the fuel vapor capture media of the evaporative emissions control system to the fuel-air mixer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Reference is made to the accompanying drawings in which particular embodiments and further benefits of the subject matter are illustrated as described in more detail in the description below, in which:

[0019] FIG. 1 is schematic view of a generic evaporative emissions control system operationally engaged with relevant components of an engine.

[0020] FIG. 2a is a perspective view of the base of a housing of an airbox comprising an evaporative emissions control system housing.

[0021] FIG. 2b is a side view of an airbox base and an airbox top shown partially transparent to show an evaporative emissions control system housing therein. [0022] FIG. 2c is a top view of the base of a housing of an airbox comprising an evaporative emissions control system housing.

[0023] FIG. 2d is a perspective view of the base of a housing of an airbox comprising an evaporative emissions control system housing with the top of the evaporative emissions control system housing removed.

[0024] FIG. 2e is a cross section of an evaporative emissions control system showing a vapor inlet.

[0025] FIG. 2f is a perspective view of the bottom of a housing of an airbox.

[0026] FIG. 2g is top perspective view of the interior of an airbox showing an evaporative emissions control system housing.

[0027] FIG. 3 is a perspective view of a motorcycle.

DETAILED DESCRIPTION OF THE DRAWINGS

[0028] The present subject matter integrates an evaporative emissions control system integrated with an airbox. By integrating the evaporative emissions control system with the airbox, the absorptive media is put in close proximity to the intake system which reduces or eliminates the need for one or more hoses or fluid connectors, and the need for separate mounting of the evaporative emissions control system is substantially eliminated.

[0029] Referring to FIGS. 1-3, it is to be understood that engines may range from very small engines such as, without limitation, those conventionally used in chain saws, trimmers, and other power tools, to enormous engines, such as, without limitation, those conventionally used in ships, locomotives, and power plants. The evaporative emissions control systems and the other subject matter provided herein is not intended to be limited to any particular engine size and may be scaled with good engineering judgment. Accordingly, the subject matter provided in FIGS. 1-3 may be considered to be of arbitrary size.

[0030] Referring now to FIG. 1, an embodiment of an evaporative emissions control system 100 operationally engaged with other relevant components is illustrated. The evaporative emissions control system 100 comprises a housing 110. The housing 110 defines a housing interior (not shown) and a housing exterior 112. The housing interior is in fluid communication with a fuel tank 120 through a first hose 132. The housing interior may contain a fuel vapor capture media (not shown). The housing interior is in fluid communication with a fuel-air mixer 140, such as, without limitation, through the fuel bowl of a carburetor, through a second hose 134. Without limitation, as shown in FIG. 1, fuel-air mixer 140 comprises, fuel bowl 142, Venturi tubes 144, and throttle body 146. FIG. 1 depicts an airbox 150 in fluid communication with throttle body 146 and with an outside atmosphere 105.

[0031] Fuel vapor may be evaporated or otherwise released from a liquid fuel, such as, without limitation, gasoline or diesel fuel, stored in a reservoir. Without limitation, in embodiments in which the associated fuel source is a fuel tank 120, fuel vapor may flow from the fuel tank 120 to evaporative emissions control system 100 where it may be absorbed.

[0032] Referring now to FIGS. 2a-2g, another embodiment of an evaporative emissions control system 200 operationally engaged with other relevant components is illustrated. The evaporative emissions control system 200 comprises a housing 210. The housing 210 defines a housing interior 211 and a housing exterior 212. The housing interior 211 is in fluid communication with a fuel tank (not shown) through a first aperture 231. The first aperture 231 is adapted to be fluidly engaged with a fuel tank by a first hose (not shown). The first hose may be any conduit adapted to convey fuel vapor from the fuel tank to the evaporative emissions control system, such as, without limitation, a fuel line. The housing interior 211 of the evaporative emissions control system 200 may contain a fuel vapor capture media 218. The housing interior 211 is in fluid communication with an outside atmosphere 205 through a fresh air vent 255. The fresh air vent 255 is a second aperture. The housing interior 211 is in fluid communication with a fuel-air mixer 240 through a third aperture 233. As illustrated, the fuel-air mixer 240 includes a throttle body 246 and a fuel injector 248. In some embodiments, the fluid communication between the third aperture 233 and the fuel-air mixer 240 may be selectably interruptable with a valve 235. The valve 235 may operate to selectably permit flow through the third aperture 233 to purge the fuel vapor capture media of captured fuel vapors.

[0033] In the embodiment shown in FIGS. 2a-2g, the airbox 250 is in fluid communication with the throttle body 246 and with an outside atmosphere 205. The airbox 250 has an airbox housing 251 defining an airbox interior 252 and an airbox exterior 253. The airbox 250 forms an air intake system 260 for a combustion engine (not shown) which may be an internal combustion engine for a two-wheeled vehicle, such as a motorcycle. In some embodiments, the air intake system 260 operatively communicates with the fuel-air mixer 240. The airbox 250 may be adapted to receive or intake air from the outside atmosphere 205 into the airbox interior 252 and to deliver air to the fuel-air mixer 240. The airbox 250 may be adapted to receive air from the outside atmosphere 205 through an airbox inlet duct 254 which provides fluid communication for air between the outside atmosphere 205 and the airbox interior 252. It should be appreciated that the shape of the airbox 250 shown in FIGS. 2a-2g is not limiting and is just one of many acceptable shapes that may be selected with good engineering judgment.

[0034] The airbox 250 may be adapted to support the evaporative emissions control system 200 at least partially contained within the airbox interior 252. In various embodiments, the evaporative emissions control system 200 is contained, partially or fully, within the airbox housing 251. In some embodiments, the evaporative emissions control system 200 is contained, partially or fully, within the evaporative emissions control system housing 210 which itself is contained within the airbox interior 252. In an embodiment, the evaporative emissions control system housing 210 is integrally formed as part of the airbox housing 251. In an embodiment, the evaporative emissions control system housing 210 is integrally formed as part of the airbox housing 251 by molding or casting a single housing to serve as both the evaporative emissions control system housing 210 and the airbox housing 251. The airbox 250 may be adapted to receive air from outside atmosphere 205 through a fresh air vent 255 which provides fluid communication for air between outside atmosphere 205 and airbox interior 252 by way of the evaporative emissions control system 200.

[0035] In various embodiments, the housing 210 of the evaporative emissions control system 200 has a first aperture 231 at or near a first end portion 257 of an elongated housing interior 211. The first aperture 231 may be adapted to receive fuel vapor from an associated fuel source, such as, a fuel tank. The housing 210 of the evaporative emissions control system 200 has a second aperture, fresh air vent 255, spaced from the first end 257 of the elongated housing interior 211. The second aperture, fresh air vent 255, is an opening open to an outside atmosphere 205 and is in fluid communication with the interior 211 of the evaporative emissions control system 200. The housing 210 of the evaporative emissions control system 200 has a third aperture 233 adapted to output fuel vapor from the evaporative emissions control system 200 to an associated fuel-air mixer 240.

[0036] The elongated housing interior 211 of housing 210 of the evaporative emissions control system 200 defines a flow path 216 for fuel vapor between the first aperture 231 and the third aperture 233. Optional partitions 214 may internally partition the elongated housing interior 211 of housing 210 of the evaporative emissions control system 200 to extend the length of the flow path 216 for fuel vapor between the second aperture 255 and the third aperture 233 through a fuel vapor capture media. [0037] In the embodiment shown in FIGS. 2a-2g, the evaporative emissions control system 200 is adapted to absorb and desorb fuel vapor. The evaporative emissions control system 200 contains fuel vapor capture media 218. The fuel vapor capture media 218 is adapted to absorb fuel vapors and desorb fuel vapor into an air stream. In an embodiment, the fuel vapor capture media 218 is activated charcoal. In a system in which a fuel tank is in fluid communication with the evaporative emissions control system 200, released fuel vapor may flow from the fuel tank to the evaporative emissions control system 200 and be absorbed partially or fully by a fuel vapor capture media 218. An evaporative emissions control system 200 containing a fuel vapor capture media 218 which has absorbed fuel vapor may desorb the absorbed fuel vapor into an air stream 256. In some embodiments, an evaporative emissions control system 200 containing a fuel vapor capture media 218 which has absorbed fuel vapor may desorb previously absorbed fuel vapor into an air stream 256 flowing into a fresh air vent 255. An air stream 256 may flow through the fuel vapor capture media 218 and flow, along with desorbed fuel vapor, out of a third aperture 233. An air stream and desorbed fuel vapor forms an air-vapor mixture which may flow out of the third aperture 233, into fuel- air mixer 240. Together the evaporative emissions control system 200 and the airbox 250 form an air intake system 260. The air intake system 260 operatively communicates with the fuel-air mixer 240, and is adapted to deliver air, the air-vapor mixture, or both to the fuel-air mixer 240.

[0038] In the fuel-air mixer 240, the fuel-air mixture is mixed with additional fuel or air or both. That is, the fuel-air mixer 240 may be adapted, to accept fuel from a fuel source, such as an associated fuel tank; to accept air and/or an air- vapor mixture from the air intake system 260; and to mix fuel and air and/or an air-vapor mixture to form a fuel-air mixture of a desired fuel to air ratio. In the embodiment shown in FIGS. 2a-2g, the airbox housing 251 is adapted to intake air into the airbox interior 252 by intaking it through airbox inlet duct 254. In this embodiment, the evaporative emissions control system 200 is contained within the airbox housing 251.

[0039] In an embodiment, the fuel air mixer 240 is in fluid communication with one or more combustion chambers of an associated internal combustion engine such that the fuel air mixer 240 is adapted to supply the fuel-air mixture to each of the one or more combustion chambers. The one or more combustion chambers are adapted to accept the fuel-air mixture and to combust the fuel-air mixture to yield work. Any or all of the one or more combustion chambers may be a cylinder of an Otto cycle engine or a Diesel cycle engine. [0040] As noted above, the presently disclosed airbox with integrated evaporative emissions control may be sized as appropriate for a given application. In some embodiments, the evaporative emissions control system is engaged with or adjacent to the airbox. In some embodiments, the evaporative emissions control system is at least partially coincident with the airbox interior. In some embodiments, the evaporative emissions control system is a subset of the airbox interior. In some embodiments, the evaporative emissions control system is contained within the airbox housing or integrally formed as part of the airbox housing.

[0041] Referring to FIGS. 2a-2g and FIG. 3, the airbox 250 forms part of the air intake system 260 for an internal combustion engine 310 as may be used in a motorcycle 300 or other vehicle. In an embodiment, the airbox 250 has a molded housing 251 where the evaporative emissions control system 200 is provided within the airbox 250, and the evaporative emissions control system 200 includes a fuel vapor capture media 218 disposed within a compartment 211 defined by the molded housing 251 of the airbox 250. As noted above, an engine for a motorcycle or other vehicle with an air intake system 260, may also include a fuel source such as a fuel tank with a conduit extending between the fuel source and the airbox, such as the first hose and the connecting fluid pathway, referenced above to fluidly engage first aperture 231 with the fuel tank. Such a conduit is configured to fluidly communicate evaporated fuel vapor from the fuel source to the fuel vapor capture media of the evaporative emissions control system within the airbox. In some embodiments, the motorcycle also includes a fuel-air mixer 240 that is configured to form a fuel-air mixture to be delivered to the combustion chamber of an engine of a vehicle such as a motorcycle. In embodiments, the airbox 250 includes an air-vapor output, such as, the port in FIG. 2g connected to the associated fuel-air mixer 240, configured to deliver the air-vapor mixture from the fuel vapor capture media of the evaporative emissions control system to the fuel-air mixer 240 . In this manner, an evaporative emissions control system is efficiently packaged for the motorcycle.

[0042] It will be appreciated by those of ordinary skill in the art, that various modifications can be made, and that many changes can be made to the disclosed embodiments without departing from the principles of the present subject matter. These and other modifications in the nature of the disclosed embodiments will be apparent to those skilled in the art from the disclosure herein, and it is understood that the foregoing descriptive matter is to be interpreted as illustrative of the present subject matter and not as a limitation.

Claims

What is claimed is:

1. A system comprising:

an airbox forming an intake air system for an internal combustion engine, the airbox having an airbox housing defining an airbox exterior and an airbox interior; and

an evaporative emissions control system engaged with the airbox housing.

2. The system as claimed in claim 1, wherein the evaporative emissions control system is contained within the airbox housing.

3. The system as claimed in claim 1, wherein the evaporative emissions control system comprises an evaporative emissions control system housing defining an evaporative emissions control system housing interior and an evaporative emissions control system housing exterior.

4. The system as claimed in claim 3, wherein the evaporative emissions control system housing interior is adjacent to or at least partially coincident with the airbox interior.

5. The system as claimed in claim 3, wherein the evaporative emissions control system housing interior is a sub- set of the airbox interior.

6. The system as claimed in claim 3, wherein at least a portion of the evaporative emissions control system housing is integrally formed as part of the airbox housing.

7. The system as claimed in claim 3, wherein the evaporative emissions control system housing is integrally molded as part of the airbox housing.

8. The system as claimed in claim 3 further comprising:

a conduit configured to fluidly communicate fuel vapor from a fuel source to the evaporative emissions control system housing interior.

9. The system as claimed in claim 3, wherein the evaporative emissions control system housing is elongated to define a first end portion and a second end portion spaced apart from the first end portion.

10. The system as claimed in claim 3, wherein the evaporative emissions control system housing comprises a first aperture, and wherein the first aperture is adapted for communication of fuel vapor between an associated fuel source and the evaporative emissions control system housing interior.

11. The system as claimed in claim 10, wherein the evaporative emissions control system housing comprises a second aperture, and wherein the second aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and an outside atmosphere.

12. The system as claimed in claim 11, wherein the evaporative emissions control system housing comprises a third aperture, wherein the third aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and a fuel-air mixer.

13. The system as claimed in claim 12, wherein the second aperture is offset from the third aperture by a region adapted to contain a fuel vapor capture media.

14. The system as claimed in claim 13, wherein the evaporative emissions control system housing is internally partitioned to provide an extended flow path for fuel vapor or air or both fuel vapor and air between the second aperture and the third aperture.

15. The system as claimed in claim 1, wherein the evaporative emissions control system contains a fuel vapor capture media adapted to absorb fuel vapor and desorb fuel vapor.

16. The system as claimed in claim 15, wherein the fuel vapor capture media is activated charcoal.

17. A system comprising:

an internal combustion engine having at least one combustion chamber adapted to receive a fuel- air mixture;

a fuel-air mixer fluidly communicating with each of the at least one combustion chambers and adapted to supply the fuel-air mixture to each combustion chamber; and

an air intake system operatively communicating with the fuel-air mixer, and adapted to deliver air or an air-vapor mixture to the fuel-air mixer,

wherein the air intake system includes

an airbox having an airbox housing defining an airbox exterior, and an airbox interior, and

an evaporative emissions control system engaged with the airbox housing.

18. The system as claimed in claim 17, wherein the evaporative emissions control system is contained within the airbox housing.

19. The system as claimed in claim 17, wherein the evaporative emissions control system comprises an evaporative emissions control system housing defining an evaporative emissions control system housing interior and an evaporative emissions control system housing exterior.

20. The system as claimed in claim 19, wherein the evaporative emissions control system housing interior is adjacent to or at least partially coincident with the airbox interior.

21. The system as claimed in claim 19, wherein the evaporative emissions control system housing interior is a sub- set of the airbox interior.

22. The system as claimed in claim 19, wherein the evaporative emissions control system housing comprises a component integrally formed as part of the airbox housing.

23. The system as claimed in claim 19, wherein the evaporative emissions control system housing is integrally molded as part of the airbox housing.

24. The system as claimed in claim 19 further comprising:

25. The system as claimed in claim 19, wherein the evaporative emissions control system housing is elongated to define a first end portion and a second end portion spaced apart from the first end portion.

26. The system as claimed in claim 19, wherein the evaporative emissions control system housing comprises a first aperture proximate to the first end portion, and wherein the first aperture is adapted for communication of fuel vapor between the associated fuel source and the evaporative emissions control system housing interior.

27. The system as claimed in claim 26, wherein the evaporative emissions control system housing comprises a second aperture, and wherein the second aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and an outside atmosphere.

28. The system as claimed in claim 27, wherein the housing of the evaporative emissions control system comprises a third aperture, and wherein the third aperture is adapted for communication of fuel vapor or air or both fuel vapor and air between the evaporative emissions control system housing interior and the fuel-air mixer.

29. The system as claimed in claim 28, wherein the second aperture is offset from the third aperture by a region adapted to contain a fuel vapor capture media.

30. The system as claimed in claim 29, wherein the evaporative emissions control system housing is internally partitioned to provide an extended flow path for fuel vapor or air or both fuel vapor and air between the second aperture and the third aperture.

31. The system as claimed in claim 17, wherein the evaporative emissions control system contains a fuel vapor capture media adapted to absorb fuel vapor and desorb fuel vapor.

32. The system as claimed in claim 31, wherein the fuel vapor capture media is activated charcoal.

33. The system as claimed in claim 32, wherein the fuel-air mixer is adapted to receive fuel from a fuel source, receive air or an air-vapor mixture from the air intake system, and

mix the fuel and either the air or the air-vapor mixture into the fuel-air mixture.

34. The system as claimed in claim 17, wherein the internal combustion engine is an Otto cycle engine or a Diesel cycle engine.

35. A motorcycle comprising:

an airbox having a molded housing, the airbox forming an intake air system for an internal combustion engine, and

an evaporative emissions control system provided within the airbox, the evaporative emissions control system including a fuel vapor capture media disposed within a compartment defined by the molded housing of the airbox.

36. The motorcycle of claim 35 further comprising:

a fuel source, and

a conduit extending between the fuel source and the airbox, the conduit configured to fluidly communicate evaporated fuel vapor from the fuel source to the fuel vapor capture media of the evaporative emissions control system within the airbox.

37. The motorcycle of claim 36 further comprising:

a fuel-air mixer configured to form a fuel-air mixture to be delivered to an engine of the motorcycle,

wherein the airbox includes an air-vapor output configured to deliver an air- vapor mixture from the fuel vapor capture media of the evaporative emissions control system to the fuel-air mixer.