Adsorptive assembly and method of making the same
An adsorptive filter/member for adsorbing a gaseous adsorbate. The filter includes two layers of a flexible polymeric material to form an area therebetween. Fasteners are located at predetermined areas across the two layer outer surfaces, the fasteners extending from the outer surface of one layer to the outer surface of the other layer. The fasteners subdivide the area into a plurality of substantially enclosed chambers. Adsorptive media is disposed within each of the plurality of chambers. The chambers are adapted to substantially evenly distribute adsorptive media throughout the filter. Throughbores extend through the filter, and receive attachment members for mounting the filter to a surface. A gaseous adsorbate flow path is in gaseous communication with one of the outer surfaces of the two layers. Each of the two layers' polymeric materials includes pores that are permeable to the gaseous adsorbate, yet are substantially impermeable to the adsorptive media.
1. An adsorptive filter for adsorbing a desired gaseous adsorbate, comprising:
a first layer of a flexible polymeric material having an outer surface;
a second layer of a flexible polymeric material spaced from the first layer to form an area between the first and second layers, the second layer having an outer surface;
a plurality of fasteners located at predetermined areas across the first and second layer outer surfaces, the plurality of fasteners extending from the outer surface of the first layer to the outer surface of the second layer, wherein the plurality of fasteners subdivides the area into a plurality of substantially enclosed chambers;
a predetermined amount of adsorptive media disposed within each of the plurality of substantially enclosed chambers, the plurality of substantially enclosed chambers adapted to substantially evenly distribute the adsorptive media throughout the filter;
a plurality of throughbores extending from the outer surface of the first layer to the outer surface of the second layer, and adapted to receive attachment members for mounting the filter to a desired surface, the plurality of throughbores located on the attachment members and the plurality of throughbores being formed from a spot weld of a portion of the first layer to a portion of the second layer; and
a gaseous adsorbate flow path in gaseous communication with one of the outer surfaces of the first and second layers;
wherein each of the first and second layer polymeric materials include pores that are permeable to the desired gaseous adsorbate, and wherein each of the first and second layer polymeric materials pores are substantially impermeable to the adsorptive media.
2. The adsorptive filter as defined in claim 1 wherein the attachment members are configured to mount the adsorptive filter a spaced distance from the desired surface, thereby forming a second gaseous adsorbate flow path between the desired surface and the other of the outer surfaces of the first and second layers.
3. The adsorptive filter as defined in claim 1 wherein the adsorptive media comprises at least one of a carbon based material, zeolites, aluminum silicates, silica gels, cyclodextrins, silicone, and mixtures thereof.
4. The adsorptive filter as defined in claim 3 wherein the carbon based material comprises particles of granular carbon, the particles having a size ranging between about 100 μm and about 200 μm.
5. The adsorptive filter as defined in claim 1 wherein the predetermined amount of adsorptive media ranges between about 0.1 grams per square inch per side of the substantially enclosed chamber and about 1 gram per square inch per side of the substantially enclosed chamber.
6. The adsorptive filter as defined in claim 1 further comprising an intermediate layer of a flexible polymeric material disposed between the first and second layers to form a first area disposed between the first layer and the intermediate layer, and a second area disposed between the intermediate layer and the second layer, and wherein the plurality of fasteners subdivides each of the first and second areas into a plurality of substantially enclosed first chambers and substantially enclosed second chambers, the plurality of first and second chambers adapted to receive the adsorptive media.
7. The adsorptive filter as defined in claim 6 wherein the intermediate layer is adapted to add rigidity to the filter.
8. The adsorptive filter as defined in claim 6 wherein the intermediate layer is permeable to the desired adsorbate and is substantially impermeable to the adsorptive media.
9. The adsorptive filter as defined in claim 1 wherein the adsorptive media has an exposed surface area ranging between about 30 square inches and about 200 square inches.
10. The adsorptive filter as defined in claim 1 wherein at least one of the first layer of polymeric material and the second layer of polymeric material layer of polymeric material comprises at least one of polyesters, polypropylenes, vinyl copolymers, polycarbonate, acetal, polyvinyl chloride, polyamides, and mixtures thereof.
11. The adsorptive filter as defined in claim 1 wherein the plurality of fasteners comprises at least one of rivets and welds.
12. The adsorptive filter as defined in claim 11 wherein the welds are at least one of sonic welds, vibration welds, hot upsetting welds, and laser welds.
13. The adsorptive filter as defined in claim 1 wherein the gaseous adsorbate comprises hydrocarbon vapors.
14. The adsorptive filter as defined in claim 1 wherein the filter is adapted to be regenerated for repeated use.
15. The adsorptive filter as defined in claim 14 wherein regeneration of the filter is accomplished by at least one of increased air flow, temperature swing adsorption, and pressure swing adsorption.
16. The adsorptive filter as defined in claim 1 wherein the filter is adapted for use in a vehicle air induction system.
17. The adsorptive filter as defined in claim 1 wherein the filter further comprises at least one selectively articulatable member adapted to substantially conform the filter relative to the desired surface.
18. The adsorptive filter as defined in claim 1 wherein the attachment members are heat staking pins.
19. The adsorptive filter as defined in claim 1 wherein the filter is a frameless adsorptive filter.
20. An adsorptive filter for adsorbing hydrocarbon vapor, comprising:
a first layer of a flexible, woven polymeric material having an outer surface;
a second layer of a flexible, woven polymeric material spaced from the first layer, the second layer having an outer surface;
an intermediate layer of a flexible polymeric, woven material disposed between the first and second layers to form a first area disposed between the first layer and the intermediate layer, and a second area disposed between the intermediate layer and the second layer;
a plurality of spot welds located at predetermined areas across the first and second layer outer surfaces, the plurality of spot welds extending from the outer surface of the first layer, through the intermediate layer, to the outer surface of the second layer, wherein the plurality of spot welds subdivides each of the first area and second area into a plurality of substantially enclosed first chambers and substantially enclosed second chambers, the plurality of first and second chambers adapted to add rigidity to the filter;
a predetermined amount of adsorptive media disposed within each of the plurality of substantially enclosed first and second chambers;
a hydrocarbon vapor flow path in gaseous communication with one of the outer surfaces of the first and second layers; and
means for mounting the filter to a desired surface, the means for mounting engaging openings in the plurality of spot welds, wherein the mounting means is configured to mount the adsorptive filter a spaced distance from the desired surface, thereby forming a second hydrocarbon vapor flow path between the desired surface and the other of the outer surfaces of the first and second layers;
wherein each of the first and second layer polymeric materials includes pores that are permeable to the hydrocarbon vapor, and wherein each of the first and second layer polymeric materials pores are substantially impermeable to the adsorptive media.
21. The adsorptive filter as defined in claim 20 wherein the filter further comprises at least one selectively articulatable member adapted to substantially conform the filter relative to the desired surface.