WO2013006362A1

WO2013006362A1 - Emission control devices for air intake systems

Info

Publication number: WO2013006362A1
Application number: PCT/US2012/044557
Authority: WO
Inventors: Caleb S. Loftin; Kyle Schumaker; Erik VERSEN
Original assignee: Meadwestvaco Corporation
Priority date: 2011-07-01
Filing date: 2012-06-28
Publication date: 2013-01-10

Abstract

An air intake emission control device includes an adsorbing element (300) and a retainer (400). The adsorbing element includes a front edge (301), a back edge (302), side edges (303) extending between the front and back edges, and a first locking component (304) positioned on the side edges. The retainer comprises a bar structure that includes a front end (401), a back end (402), a lateral side (403) connecting the front and back ends, and a second locking component (404) positioned on the lateral side. The first locking component on the side edges of the adsorbing element engages the second locking component on the retainer and retains the adsorbing element in a predetermined structure. The first locking component may have a complimentary structure to the second locking component. The device may be placed in air intake ductwork, in an extending conduit positioned between the air intake ductwork and the air outlet ductwork, or both.

Description

Patent Application for

EMISSION CONTROL DEVICES FOR AIR INTAKE SYSTEMS BACKGROUND OF THE DISCLOSURE

[0001] An increase in environmental concerns has continued to drive strict regulations of the hydrocarbon emissions from automotives into the environment, even when the vehicle is not operating. The great majority of internal combustion engines in use today are fuel-injected engines. When a fuel-injected engine is switched off after use, a small amount of residual fuel volatilizes and escapes from the injector tips. While a vehicle is sitting over time after use, this evaporated fuel may pass outwardly through the intake manifold, the intake air ducts and air filter, and may escape into an atmosphere contributing to air pollution. Therefore, it would be desirable to minimize this type of inadvertent evaporative emissions leakage.

[0002] One approach to abate the hydrocarbon emissions from the intake manifold after an engine shutdown is to use an air intake filter-like device having a hydrocarbon adsorbing element. One drawback of these air intake emission control devices is that the devices may act as an obstruction to the air flowing to the engine, thus causing a pressure drop in the airflow to the engine.

[0003] U.S. Patent Publication No. 2004/0099253 discloses an emission control device for an engine air induction system. The device comprises an adsorbing element being shaped to conform to the shape of air intake ductwork with the adsorbent material forming the walls of the element.

[0004] U.S. Patent No. 7,168,417 describes a hydrocarbon trapping device for an engine’s air intake system comprising: a conduit in fluid connection with the air intake system and including a wall; an adsorbing element positioned within the conduit wall; and a retainer extending from an inner surface of the conduit wall. The adsorbing element includes a leading edge, a trailing edge and side edges defining a flow path extending between the leading and trailing edges. The retainer engages the side edges of the absorbing element and secures the adsorbing element within the conduit wall.

[0005] U.S. Patent No. 7,222,612 describes a low-resistance hydrocarbon-adsorptive cartridge for an air intake system of internal combustion engine, comprising a housing having an opening for air intake passage and a hydrocarbon-adsorptive sheet positioned within the housing and across the opening. A plurality of radial retainers is used to form the adsorptive sheet into a spiral structure disposed within the opening of the housing and to maintain the spacing between the convolutions of the spiral structure. Alternatively, the convolutions of the adsorbent sheet are formed by using a plurality of individual concentric cylindrical sheet elements. SUMMARY OF THE DISCLOSURE

[0006] An air intake emission control device includes an adsorbing element and a retainer. The adsorbing element includes a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges. The retainer comprises a bar structure that includes a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side. The first locking component on the side edges of the adsorbing element engages the second locking component on the retainer and retains the adsorbing element in a

predetermined structure. The first locking component may have a complementary structure to the second locking component. The device may be placed in an air intake ductwork, in an extending conduit positioned between the air intake ductwork and the air outlet ductwork, or both. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1A shows one embodiment of the disclosed air intake emission control device having an adsorbing element positioned inside an air intake duct;

[0008] FIG. 1B shows one embodiment of the disclosed emission control device having an extending conduit connecting to an air intake duct and an adsorbing element positioned inside the extending conduit;

[0009] FIG. 2A shows one embodiment of the disclosed device wherein the retainer is a bar structure including a front end, back end, lateral side extending between the front and back ends, and two locking components on the lateral side;

[0010] FIG. 2B shows a perspective view of the disclosed device of FIG. 2A wherein the adsorbing element is assembled with the retainer;

[0011] FIG. 3 shows one embodiment of the disclosed emission control device capable of interacting with an air sensor device, wherein the retainer bar includes a receiving structure to receive the air sensor device; [0012] FIG. 4A illustrates one embodiment of the disclosed device, wherein the retainer comprises a bar structure including two locking components, a supporting structure, and a connecting structure extending between the bar structure and the supporting structure;

[0013] FIG. 4B illustrates one embodiment of the method of preparing the device of FIG. 4A, including wrapping an adsorbent material around the retainer such that the locking components on the adsorbing material and the retainer engage each other to form and retain a predetermined structure of the adsorbing element;

[0014] FIG. 4C is a cross-section view of the emission control device obtained from the method of FIG. 4A;

[0015] FIG. 4D is a cross-section view of one embodiment of the disclosed device wherein the retainer has one bar structure with locking component, three supporting structures, and one connecting structure connecting the bar structure to the three supporting structures;

[0016] FIG. 4E shows one embodiment of the disclosed device wherein the retainer has a bar structure with locking components, a supporting structure, and a connecting structure connecting the back end of the bar structure to the back end of the supporting structure;

[0017] FIG. 5A shows one embodiment of the disclosed device wherein the retainer comprises a first bar structure including two locking components, a second bar structure including two locking components, and two connecting structures connecting the first and second bar structures;

[0018] FIG. 5B shows one embodiment of the disclosed device wherein the retainer comprises a first bar structure including two locking components, a second bar structure including two locking components, and three connecting structures connecting the first and second bar structures;

[0019] FIG. 5C is a cross-section view of one embodiment of the disclosed device wherein the retainer has three bar structures with locking components and a connecting structure connecting the three bar structures together;

[0020] FIG. 5D is a perspective view of the disclosed device showing the adsorbing element wrapping around the retainer of FIG. 5A;

[0021] FIG. 6A illustrates one embodiment of the method of preparing the disclosed device, including wrapping an adsorbent material around the retainer such that the locking components on the adsorbent material and the retainer engage each other to form and retain a predetermined structure of the adsorbing element; [0022] FIG. 6B is a front view of the emission control device obtained from the method of FIG. 6A;

[0023] FIG. 7A is a perspective view of the emission control device of FIG. 6B;

[0024] FIG. 7B is a cross-sectional view of the emission control device of FIG. 6B;

[0025] FIG. 8 shows one embodiment of the disclosed device wherein each retainer comprises an inner bar with two locking components and an outer bar with two locking components, the outer bar connecting to the inner bar in a hinge configuration;

[0026] FIG. 9A illustrates one embodiment of the method of preparing the disclosed device, including position the side edges of the self-forming adsorbing element between the inner and outer bars of the retainer such that the locking components on the adsorbing element and the retainer engage each other to retain a predetermined structure of the adsorbing element;

[0027] FIG. 9B is a front view of the emission control device obtained from the method of FIG. 9A;

[0028] FIG.10A is a perspective view of the device of FIG. 9B;

[0029] FIG.10B is a perspective view of the device wherein four retainers are used to retain the adsorbing element in a predetermined structure, each retainer including an inner bar and an outer bar; and

[0030] FIG. 11 illustrates one embodiment of the method of preparing the disclosed device, including providing a retainer comprising a first bar structure and second bars structure, each with an inner bar and outer bar connected to the inner bar in a hinge configuration; positioning the side edges of an adsorbent material between the inner and outer bars of each bar structure such that the locking components on the adsorbent material and the retainer engage each other to form and retain a predetermined structure of the adsorbing element. DESCRIPTION OF THE DISCLOSURE

[0031] The present disclosures now will be described more fully hereinafter, but not all embodiments of the disclosure are shown. While the disclosure has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. [0032] Reference will now be made to the drawings, wherein like numerals may refer to like components. The drawings are not necessarily drawn to scale.

[0033] The emission control device of present disclosure may include an adsorbing element placed inside the air intake system (AIS) ductwork as shown in Figure 1A.

Alternatively and additionally, the device may include an adsorbing element placed in an extending conduit positioned between the air intake ductwork and the air outlet ductwork as illustrated in Figure 1B.

[0034] Figure 1A shows one embodiment of the disclosed emission control device having an adsorbing element positioned inside the AIS ductwork. The AIS emission control device 100 includes an air intake plate 101, an air intake duct 102 connecting to the air intake plate 101, and an adsorbing element 300 positioned inside the air intake tube 102.

[0035] Figure 1B shows one embodiment of the disclosed emission control device having an adsorbing element placed inside an extending conduit positioned between the AIS ductwork and the air outlet ductwork. The AIS emission control device 100 may include air intake plate 101, an air intake duct 102 having one end connecting to the air intake plate 101, an extending conduit 200 connecting to the other end of the air intake duct 102, and an adsorbing element 300 positioned inside the extending conduit 200. The extending conduit 200 may be a one-piece structure as shown in Figure 1B. Alternatively, the extending conduit 200 may be multiple-piece structure. Although the extending conduit is illustrated as a cylinder structure in Figure 1B, it is understood that the extending conduit may have any appropriate alternative design.

[0036] A particular embodiment of the disclosed emission control device may include: an adsorbing element comprising a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges; and a retainer comprising a bar structure that includes a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side. The second locking component on the retainer engages the first locking component and retains the adsorbing element in a predetermined structure. The side edges may function as the walls of adsorbing element. The first locking component may have a complementary structure to the second locking component.

[0037] In some embodiments, the adsorbing element may be self-formed into a predetermined structure, and the retainer is used to retain the predetermined structure of the adsorbing element. Figures 2–3 and 8–10 show non-limiting examples of such embodiments wherein the adsorbing element is self-formed into a predetermined structure and the retainer retains the self-formed structure.

[0038] In some embodiments, the retainer assists in forming the adsorbing element into a predetermined structure as well as in retaining the predetermined structure of the adsorbing element. Figures 4–7 and 11 show non-limiting examples of such embodiments wherein the retainer assists in both the forming and retaining the adsorbing element in the predetermined structure.

[0039] Figures 2A and 2B show one embodiment of the disclosed emission control device comprising an absorbing element 300 and a retainer 400. The absorbing element 300 comprises a front edge 301, a back edge 302, side edges 303 extending between the front and back edges, and a first locking component 304 positioned on the side edges 303. The retainer 400 has a bar structure comprising a front end 401, a back end 402, a lateral side 403 connecting the front and back ends, and a second locking component 404 positioned on the lateral side 403. The second locking component 404 engages the first locking component 304 and retains the adsorbing element 300 in a predetermined structure. As shown in Figure 2A, the first locking component 304 has a slot structure, and the second locking component 404 has a complementary protrusion structure. The side edges 303 forms the walls of the adsorbing element 300 and defines the air intake flow path along the longitudinal axis of the adsorbing element. The self-forming adsorbing element 300 may be formed by rolling or folding an adsorbent sheet into a predetermined structure as shown in Figure 2A, and then the retainer 400 retains the adsorbing element in the predetermined structure as shown in Figure 2B. Although Figure 2 shows the adsorbing element being prepared by rolling or folding the adsorbent sheet, one of ordinary skill in the art understands that the adsorbing element may be formed into any predetermined structure by other techniques without departing from the scope of present disclosure.

[0040] Figure 3 illustrates one embodiment wherein the disclosed emission control device may interact with the air sensor device. The retainer 400 includes a front end 401, a back end 402, a lateral side 403 connecting the front and back ends, a second locking structure 404 on the lateral side, and a receiving structure R positioned on the lateral 403 and configured to receive an air sensor device S. The adsorbing element 300 includes: a front edge 301, a back edge, side edges 303 connecting the front and back edges, a first locking component 304, and a cut out structure on the side edges of the adsorbing element and having a complimentary structure to the receiving structure R on the retainer 400. The adsorbing element 300 is positioned in a plane along an intake airflow F such that the intake air flows along the longitudinal axis of the adsorbing element. The device is assembled such that: the second locking structure 404 engages the first locking structure 304 to retain a predetermined structure of the adsorbing element, and the receiving structure R of the retainer aligns with the cut out portion of the absorbing element to allow the connection between the air sensor device S and the receiving structure R through the cut off portion on the side edges of the adsorbing element.

[0041] In one embodiment of the disclosed device, the retainer may comprise: a bar structure including a second locking component; a supporting structure, and a connecting structure connecting the bar structure to the supporting structure. The bar structure comprises a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side. The device includes an adsorbing element comprising a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges. The side edges may form the walls of the adsorbing element. The second locking component of the retainer engages the first locking component and retains the adsorbing element in the predetermined structure. The first locking component may have a complementary structure to the second locking component. Figure 4 shows a non-limiting example of such embodiment.

[0042] Figure 4A shows one embodiment of the retainer. A retainer 500 include a bar structure 500A, a supporting structure 500B, and a connecting structure X connecting between the bar structure 500A and the supporting structure 500B. The bar structure 500A comprises a front end 501, a back end 502, a lateral side 503 connecting the front and back ends, a second locking structure 504 on the lateral side.

[0043] Figure 4B shows one embodiment of the method of preparing the device using the retainer of Figure 4A. The method comprises: providing an adsorbent material 600 that includes a front edge 601, a back edge 602, side edges 603 extending between the front and back edges, and a first locking component 604 positioned on the side edges; wrapping or folding the absorbent material 600 around the retainer 500 such that the first locking components 604 on the side edges 603 of the absorbent material engages the second locking component 504 on the lateral side of the bar structure 500A to form the adsorbent material into an adsorbing element 300 of a predetermined structure and to retain the predetermined structure of the adsorbing element. Figure 4C is a cross-sectional view of the emission control device obtained from the method of Figure 4B. The adsorbing element 300 has a hollow cylindrical structure with side edges 303 wrapping around the retainer 500 and the locking component 304 engaging with the locking component 504 on the lateral side of the bar structure 500A. The adsorbing element has an axial axis and a longitudinal axis. The side edges 303 may form the walls of the device and define the airflow path along the longitudinal axis.

[0044] Figure 4D is a cross-sectional view of one embodiment of the disclosed device wherein a retainer 500 comprises: a bar structure 500A including a locking component 504; three supporting structures 500B, 500C, 500D; and a connecting structure X connecting the bar structure 500A and the supporting structures 500B–500D together. The device includes an adsorbing element 300 wrapping around the retainer 500 and having the locking component on the side edges 303 engaging with the locking component 504 on the lateral side of the bar structure 500A.

[0045] Figure 4E shows one embodiment of the retainer. A retainer 500 may include a bar structure 500A, a supporting structure 500B, and a connecting structure X connecting between the bar structure 500A and the supporting structure 500B. The bar structure 500A comprises a front end 501A, a back end 502A, a lateral side connecting the front and back ends, a second locking structure 504 on the lateral side. The supporting structure 500B comprises a front end 501B, a back end 502B, and a lateral side connecting the front and back ends. The connecting structure X connects the back end 502A of the bar structure to the back end 502B of the supporting structure, thereby connecting the bar structure and the supporting structure together.

[0046] In one embodiment of the disclosed device, the retainer may comprise: a first bar structure; a second bar structure, and a connecting structure connecting the first and second bar structures. The first bar structure comprises a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side. The second bar structure comprises a front end, a back end, a lateral side connecting the front and back ends, and a third locking component positioned on the lateral side. The device includes an adsorbing element comprising a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges. The side edges may form the walls of the adsorbing element. The first locking component of the adsorbing element engages the second locking component on the first bar structure and the third locking component on the second bar structure of the retainer and retains the adsorbing element in a predetermined structure. The second locking component on the first bar structure may have same structure as the third locking component on the second bar structure. The first locking component may have a complementary structure to the second locking component, or the third locking component, or both. Figure 5 shows a non-limiting example of such embodiment.

[0047] Figure 5A shows one embodiment of the retainer. A retainer 500 include a first bar structure 500A, a second bar structure 500B, and connecting structures X1 and X2 positioned between the first and second bar structures 500A and 500B. The first bar structure 500A comprises a front end 501A, a back end 502A, a lateral side connecting the front and back ends, a second locking structure 504A on the lateral side. The second bar structure 500B comprises a front end 501B, a back end 502B, a lateral side connecting the front and back ends, a second locking structure 504B on the lateral side. The connecting structure X1 connects the front end 501A of the first bar 500A to the front end 501B of the second bar 500B. The connecting structure X2 connects the back end 502A of the first bar 500A to the back end 502B of the second bar 500B.

[0048] Figure 5B shows another embodiment of the retainer 500, which may include a first bar structure 500A, a second bar structure 500B, and connecting structures X1, X2, X3 positioned between the first and second bar structures 500A and 500B. Each bar structure comprises a front end, a back end, a lateral side connecting the front and back ends, a second locking structure 504 on the lateral side. The connecting structure X1 connects the front ends of the first and second bar 500A, 500B together. The connecting structure X2 connects between the lateral sides of the first and second bar 500A, 500B together. The connecting structure X3 connects between the back ends of the first and second bar 500A, 500B together.

[0049] Figure 5C is a cross-sectional view of one embodiment of the disclosed device wherein a retainer 500 include a first bar structure 500A, a second bar structure 500B, and a third bar structure 500C, and a connecting structure X connecting the first, second and third bar structures together. Each bar structure comprises a front end, a back end, a lateral side connecting the front and back ends, and a second locking structure 504 on the lateral side. An adsorbing element 300 wraps around the retainer 500 with its locking components engaging the locking components (504A, 504B, 504C) of the retainer 500 and retaining the predetermined structure of the adsorbing element 300. [0050] Figure 5D is a perspective view of one embodiment of the disclosed device wherein a retainer 500 include a first bar structure, a second bar structure, and at least one connecting structure X connecting the first and second bar structures. An adsorbing element comprises a front edge 301, a back edge 302, side edges 303 extending between the front and back edges, and a first locking component 304 positioned on the side edges. The adsorbing element 300 wraps around the retainer 500 with its locking component 304 engaging the locking components 504 of the retainer 500 and retaining the predetermined structure of the adsorbing element 300. As shown in Figure 5D, the adsorbing element 300 may have a hollow cylindrical structure with the side edges 303 functioning as the walls of the element and defining an airflow path along the longitudinal axis of the element. The diameter (i.e., axial axis) of the adsorbing element may be modified by varying the length of the connecting structure X of the retainer. The length (i.e., longitudinal axis) of the adsorbing element may be modified by adjusting the length of the side edges 303 of the adsorbing element.

[0051] Figure 6A illustrates an example of one embodiment of the disclosed device wherein the retainer has a hollow cylindrical structure with openings on side walls. The retainer 500 may include a first bar structure 500A, a second bar structure 500B, a third bar structure 500C, a fourth bar structure 500D, and connecting structures X1, X2 connecting the bar structures together such that a hollow cylindrical structure is formed having openings and locking structures on the side walls. Each bar structure may include a front end 501, a back end 502, a lateral side 503 extending between the front and back ends, and a locking component 504 positioned on the lateral side. The devise includes an adsorbing element 300 formed from an adsorbent material 600 that comprises a front edge 601, a back edge, side edges 603 extending between the front and back edges, and a locking component 604 positioned on the side edges. The adsorbent sheet 600 wraps around an exterior perimeter of the retainer 500 such that the locking components 604 on the side edges 603 of the absorbent material engages the locking component 504 on the lateral side of the bar structures 500 to form the adsorbent material into an adsorbing element 300 of a predetermined structure and to retain the predetermined structure of the adsorbing element. Figures 6B, 7A and 7B are front view, perspective view, and cross-sectional view of the emission control device obtained from Figure 6A. As shown, the adsorbing element 300 may have a hollow cylindrical structure with the side edges 303 functioning as the walls of the element and defining an airflow path along the longitudinal axis of the element. [0052] In a particular embodiment of the disclosed device, the retainer may comprise a bar structure including an inner bar and an outer bar connected to the inner bar in a hinge configuration. The inner bar and outer bar, each includes a front end, a back end, a lateral side extending between the front and back ends, and a locking component on the lateral side. The adsorbing element comprises a front edge, a back edge, side edges connecting the front and back edges, and a locking component on the side edges. The adsorbing element is assembled with the retainer such that: the side edges of the adsorbing element is positioned between the inner and outer bars of the retainer, and the locking component on the side edges of the adsorbing element engages with the locking components on the lateral sides of the inner and outer bars of the retainer to retain the adsorbing element in the predetermined structure. The side edges of the adsorbing element may form the walls of the disclosed device and define the airflow path. Figures 8–10 show non-limiting examples of such embodiment.

[0053] In the embodiment of Figure 8, the retainers 800, 900 are used to retain the desired structure of the adsorbing element. Each retainer comprises: an inner bar having a front end, a back end, a lateral side, and a locking component on the lateral side; an outer bar having a front end, a back end, a lateral side, and a locking component on the lateral side, the outer bar connecting to the inner bar via a hinging mechanism. For example, the retainer 800 comprises an inner bar 800A and an outer bar 800B. The inner bar 800A comprises a front end 801, a back end 802A, a lateral side 803A, and a locking component 804 on the lateral side. The outer bar 800B comprises a front end 801, a back end 802B, a lateral side 803B, and a locking component 805 on the lateral side. The outer bar 800B connects to the inner bar 800A at the front end 801 via a hinge mechanism. An adsorbing element 300 comprises a front edge 301, a back edge 302, side edges 303 extending between the front and back edges, and a locking component 304 positioned on the side edges. The locking component 304 on the side edges of the adsorbing element may engage the locking components 804 on the inner bar 800A and the locking component 805 on the outer bar of the retainer to retain the predetermined structure of the adsorbing element 300.

[0054] Figure 9 shows one embodiment of the method of preparing the device using the retainers of Figure 8 and a self-forming adsorbing element 300. The method comprises: providing a self-forming adsorbing element 300 that includes a front edge 301, a back edge 302, side edges 303 extending between the front and back edges, and a locking component positioned on the side edges; preparing a retainer 800 that includes an inner bar 800A and an outer bar 800B, each bar comprising a front end 801, a back end 802A/802B, a lateral side, and a locking component 804/805 on the lateral side, the inner bar 800A connecting to the outer bar 800B at the front end 801 by way of a hinge; and assembling the adsorbing element 300 with the retainer 800 such that the side edges 303 of the adsorbing element is positioned between the inner bar 800A and the other bar 800B of the retainer, and the locking component on the side edges of the adsorbing element engages the locking component 804 on the inner bar and the locking component 805 on the outer bar of the retainer to retain the self- formed, predetermined structure of the adsorbing element 300. Figures 9B and 10A are the side view and perspective view, respectively, of the resulting device, wherein the self- forming adsorbing element 300 has a hollow cylindrical structure with side edges 303 functioning as the walls of the device and defining the airflow path along the longitudinal axis of the cylindrical adsorbing element 300. Figure 10B shows a perspective view of the device wherein four retainers (800, 900, 1000, and 1100) are used to retain the predetermined structure of the adsorbing element 300.

[0055] In one embodiment of the disclosed device, the retainer may comprise: a first bar structure including an inner bar and an outer bar hingedly connected to the inner bar; a second bar structure including an inner bar and an outer bar hingedly connected to the inner bar; and a connecting structure connecting the first and second bar structures. The inner bar and outer bar, each includes a front end, a back end, a lateral side extending between the front and back ends, and a locking component on the lateral side. The adsorbing element comprises a front edge, a back edge, side edges connecting the front and back edges, and a locking component on the side edges. The adsorbing element is assembled with the retainer such that the side edges of the adsorbing element is positioned between the inner and outer bars of the retainer; the locking component on the side edges of the adsorbing element engages with the locking components on the lateral sides of the inner and outer bars of the first retainer; and the locking component on the side edges of the adsorbing element engages with the locking components on the lateral sides of the inner and outer bars of the second retainer to retain the adsorbing element in the predetermined structure. Figure 10 shows a non-limiting example of such device and one embodiment of the method of preparing such device.

[0056] In another embodiment, the retainer of Figure 10 comprises: a first bar structure including an inner bar 800A and an outer bar 800B hingedly connected to the inner bar; a second bar structure 900 including an inner bar 900A and an outer bar 900B hingedly connected to the inner bar; and a connecting structure X connecting the first and second bars 800, 900. The inner bar of each the first and second bars 800A/900A includes a front end 801/901, a back end 802A/902A, a lateral side extending between the front and back ends, and a locking component 804/904 on the lateral side. The outer bar of each the first and second bars 800B/900B includes a front end 801/901, a back end 802B/902B, a lateral side extending between the front and back ends, and a locking component 805/905 on the lateral side, wherein the outer bar 800B/900B hingedly connects to the inner bar 800A/900A at the front edge 801/901. The adsorbent material 600 wraps around the retainer such that: the locking components 604 on the side edges 603 of the absorbent material engages the locking component 804 on the inner bar and the locking component 805 on the outer bar of the retainer 800; or the locking components 604 on the side edges 603 of the absorbent material engages the locking component 904 on the inner bar and the locking component 905 on the outer bar of the retainer 900; or both to form the adsorbent material 600 into an adsorbing element having a predetermined structure and to retain such predetermined structure of the adsorbing element.

[0057] Although the illustrated figures show the adsorbing element in a hollow cylindrical shape, one of ordinary skill in the art understands that the disclosure is readily applicable to the adsorbing elements of other structures, shapes, or size. Non-limiting examples of other structures are rectangular, square, oblong, and the like. Different designs of the adsorbing element may be chosen to provide a predetermined air flow resistance and adsorbent surface area for the intended applications.

[0058] A variety of complementary structures may be used for the locking components of present disclosure. For example, as shown in the representatives figure, the locking component on the adsorbing element may be a slot structure and the locking component on the retainer may be a complementary protrusion structure, or vice versa. One of ordinary skill in the art understands that other complementary structures having different sizes, configurations, shapes, orientations, and positions could alternatively be employed, and the scope of the disclosure is not limited to the specific sizes, configurations, shapes, orientations, and positions shown in the representative figures.

[0059] In one embodiment, the adsorbing element may comprise a substrate and an adsorbent. The substrate may be derived from a variety of materials. Non-limiting examples of suitable substrates may include paper, plastic, foam, composite, membrane, woven materials, non-woven materials, or combinations thereof. Many known adsorbents may be used in the present disclosure. Examples of adsorbents include, but are not limited to, activated carbon, charcoal, zeolite, kaolin, titania, ceria, or combinations thereof. Examples of the carbon forms suitable for use in the present disclosure may include, but are not limited to, fibers, particulates, or combinations thereof. Activated carbon suitable for use in the present disclosure may be derived from various carbon sources. Non-limiting examples of carbon sources may include wood, wood dust, wood flour, cotton linters, peat, coal, coconut, lignite, carbohydrates, petroleum pitch, petroleum coke, coal tar pitch, fruit pits, fruit stones, nut shells, nut pits, sawdust, palm, vegetables such as rice hull or straw, synthetic polymer, natural polymer, lignocellulosic material, or combinations thereof. Furthermore, the activated carbon may be produced using a variety of processes including, but not limited to, chemical activation, thermal activation, or combinations thereof.

[0060] In one embodiment, the adsorbing element may comprise an activated carbon sheet.

[0061] The retainer may be formed for various materials including, but not limited to, plastic, rubber, composite, stainless steel, aluminum, powder coated metal, or the like.

[0062] A variety of materials may be used for the extending conduit. Non-limiting examples of materials suitable for the extending conduit are plastics such as polyolefin, polystyrene, polyurethane, nylon, polypropylene; composite; rubber; stainless steel;

aluminum; powder coated metal; and the like.

[0063] When desired, the disclosed emission control device may further include a filter for removing particulate matters from a fluid stream during an operation of the internal combustion engine.

[0064] During engine operation, the fluid stream flows through the disclosed emission control device that is in communication with an engine combustion chamber or chambers through a carburetor or intake manifold. In this manner, the intake air flows through the disclosed device prior to being introduced to a combustion chamber. After the engine shutdown, the contaminant-laden air stream from the combustion chamber may backflow through into the disclosed device. Any hydrocarbons vapor accumulating in the disclosed device or migrating from the intake manifold will pass through the adsorbing element of the device, and the hydrocarbon vapors in the contaminant-laden air are adsorbed onto the adsorbing element before the treated air is discharged to the atmosphere. Once the engine is turned on, fresh air from the external environment flows into the disclosed device, desorbs some of the previously adsorbed hydrocarbons on the adsorbing element, and carries these hydrocarbon vapors through to the combustion chamber, wherein the fluid will be combusted along with the fuel.

[0065] The contaminants in the laden fluid stream may include, but are not limited to, saturated and unsaturated hydrocarbons utilized in fuels and byproducts caused by combustion; certain carbon oxides such as carbon monoxide, nitrates, sulfides, ozone, and the like; or combinations thereof.

[0066] The emission control device of the present disclosure may be for use in removing residual fuel vapor, after the engine has been turned off, from within an engine's intake system or downstream of a throttle body.

[0067] When desired, the disclosed emission control device may be used in combination with other known air intake emission control devices. Examples of the supplemental air intake emission control devices suitable for use with the disclosed device include, but are not limited to, a flow-by air intake emission control device with an adsorbing element locating in an air duct, a flow-through air intake emission control device having an adsorbing element locating in an air duct, and combinations thereof.

[0068] The disclosed emission control device may have enhanced adsorption efficiency for hydrocarbons emitted from an engine’s intake manifold into an atmosphere during engine shutdown without substantially imparting airflow resistance to the air induction system.

[0069] It will be recognized that as used herein, directional references such as "front", "back", "end", "side", "inner", and "outer" do not limit the respective components to such orientation, but merely serve to distinguish these components from one another.

[0070] While the invention has been described by reference to various specific embodiments, it should be understood that numerous changes may be made within the spirit and scope of the inventive concepts described. Accordingly, it is intended that the invention not be limited to the described embodiments, but will have full scope defined by the language of the following claims.

Claims

We Claim:

1. An emission control device for an air intake system, comprising:

an adsorbing element including a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges; and

a retainer comprising a bar structure that includes a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side,

wherein the locking component on the side edges of the adsorbing element engages the locking component on the retainer and retains the adsorbing element in a predetermined structure. 2. The device of Claim 1, wherein the first locking component has a complementary structure to the second locking component. 3. The device of Claim 2, wherein the first locking component includes a slot structure and the second component includes a complementary protrusion structure.

2. The device of Claim 1, wherein:

the retainer further includes a receiving structure positioned on the lateral side and configured to receive an air sensor device;

the adsorbing element further includes a cut out structure on the side edges, the cut out structure having a complimentary structure to the receiving structure on the retainer; and the receiving structure of the retainer aligns with the cut out structure of the absorbing element to allow a connection between the air sensor device and the receiving structure of the retainer through the cut out structure of the adsorbing element.

3. The device of Claim 1, wherein the retainer further comprises:

a supporting structure; and

a connecting structure extending between the bar structure and the supporting structure.

4. The device of Claim 1, wherein the retainer comprises:

a first bar structure including a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side;

a second bar structure including a front end, a back end, a lateral side connecting the front and back ends, and a third locking component positioned on the lateral side; and

a connecting structure extending between the first and second bar structures, wherein the first locking component of the adsorbing element engages the second locking component on the first bar structure and the third locking component on the second bar structure of the retainer and retains the adsorbing element in a predetermined structure.

5. The device of Claim 4, wherein:

the retainer is a hollow cylindrical structure comprising a first end, a second end, and a longitudinal side connecting the first and second ends;

the hollow cylindrical structure defines a front opening, a back opening, and a side opening along the longitudinal side of the cylindrical structure;

the connecting structure forms the first end, the second end, or both of the cylindrical structure; and

the lateral side of the bar structures forms the longitudinal side of the cylindrical structure.

6. The device of Claim 1, wherein the bar structure comprises:

an inner bar including a front end, a back end, a lateral side extending between the front and back ends, and a second locking component on the lateral side; and

an outer bar connected to the inner bar via a hinge mechanism, the outer bar including a front end, a back end, a lateral side extending between the front and back ends, and a third locking component on the lateral side,

wherein the adsorbing element is assembled with the retainer such that:

the side edges of the adsorbing element is positioned between the inner and outer bars of the retainer, and

the first locking component on the side edges of the adsorbing element engages with the second and third locking components on the lateral sides of the inner and outer bars of the retainer to retain the adsorbing element in the predetermined structure.

7. The device of Claim 6, wherein the retainer comprises: a first bar structure including an inner bar and an outer bar that is connected to the inner bar via a hinge mechanism, each bar including a front end, a back end, a lateral side extending between the front and back ends, and a locking component on the lateral side; a second bar structure including an inner bar and an outer bar that is connected to the inner bar via a hinge mechanism, each bar including a front end, a back end, a lateral side extending between the front and back ends, and a locking component on the lateral side; and a connecting structure connecting the first and second bar structure,

wherein the adsorbing element is assembled with the retainer such that:

the side edges of the adsorbing element is positioned between the inner and outer bars of the first bar structure and between the inner and outer bars of the second bar structure, and

the locking component on the side edges of the adsorbing element engages with the locking components on the retainer to retain the adsorbing element in the predetermined structure.

8. The device of Claim 1, wherein the adsorbing element comprises a substrate and an adsorbent.

9. The device of Claim 8, wherein the substrate includes a member selected from the group consisting of paper, plastic, foam, composite, membrane, and combinations thereof. 10. The device of Claim 8, wherein the absorbent includes a member selected from the group consisting of activated carbon, charcoal, zeolite, kaolin, titania, ceria, and

combinations thereof.

10. The device of Claim 1, wherein the adsorbing element comprises an activated carbon sheet.

11. The device of Claim 1, wherein retainer comprises a member selected from the group consisting of plastic, rubber, composite, stainless steel, aluminum, powder coated metal, and combinations thereof.

12. The device of Claim 1, further comprising a filter for removing particulate matters.

13. The device of Claim 1 positioned in an extending conduit connecting air intake ductwork and an air outlet ductwork, or in the air intake ductwork, or both.

14. The device of Claim 1, wherein the adsorbing element has a hollow cylindrical structure.

15. An air intake system for an internal combustion engine, comprising the device of Claim 1.

16. A method of preparing an emission control device for an air intake system, comprising: providing an adsorbing element including a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges;

providing a retainer comprising a bar structure, the bar structure including a front end, a back end, a lateral side connecting the front and back ends, and a second locking component positioned on the lateral side; and

engaging the first locking component on the side edges of the adsorbing element with the second locking component on the retainer to retain the adsorbing element in a predetermined structure.

17. The method of Claim 16, comprising providing the adsorbing element wherein the adsorbing element is self-formed into the predetermined structure prior to engaging with the retainer.

18. The method of Claim 16, further comprising:

providing an adsorbent material including a front edge, a back edge, side edges extending between the front and back edges, and a first locking component positioned on the side edges; and

shaping the adsorbent material around the retainer to form the adsorbing element having the predetermined structure.

19. The method of Claim 18, comprising shaping the adsorbent material around the retainer into a hollow cylindrical structure.

20. The method of Claim 18, further comprising preparing an adsorbent material, wherein the adsorbent material comprises an activated carbon sheet.