Emission control devices for air intake systems

Abstract

An air intake emission control device includes a self -forming adsorbing element ( 200 ) comprising a front edge ( 301 ), a back edge ( 302 ), side edges ( 303 ) extending between the front and back edges and defining an air intake flow path, and a first locking component ( 301 a ) on the front edge, back edge, or both. The device further includes a second locking component ( 403 ) configured to engage the first locking component and retain the self-forming adsorbing element in a predetermined structure. The second locking component may be located on the adsorbing element itself such that the adsorbing element is self-formed and self-locked in the predetermined structure. Alternatively, the device may include an end cap ( 401 ) and the second locking structure may be located on the end cap. The device may be placed in air intake ductwork, in an extending conduit positioned between the an air intake ductwork and the air outlet ductwork, or both.

We claim: 
     
         1 . An emission control device for an air intake system, comprising:
 an adsorbing element including a front edge, a back edge, and side edges extending between the front and back edges and defining an airflow path, the adsorbing element being self-formed into a predetermined structure, the adsorbing element comprising a first locking component on at least one of the front edge and the back edge; and   a second locking component engaging the first locking component and retaining the self-forming adsorbing element in the predetermined structure.   
     
     
         2 . The device of  claim 1 , wherein the second locking component is located on the adsorbing element such that the adsorbing element is self-formed and self-locked in the predetermined structure. 
     
     
         3 . The device of  claim 2 , wherein the first locking component has a complementary structure to the second locking component. 
     
     
         4 . The device of  claim 3 , wherein the first locking component includes a slot structure and the second component includes a complementary tab structure. 
     
     
         5 . The device of  claim 2 , wherein the adsorbing element is formed from an adsorbent sheet having a first end and a second end opposite to the first end,
 the adsorbent sheet comprising a first locking component on the first end and a second locking component at a predetermined distance from the first locking component.   
     
     
         6 . The device of  claim 1 , further comprising:
 an end cap including a base rim, the second locking component being positioned on the base rim of the end cap.   
     
     
         7 . The device of  claim 6 , wherein the first locking component has a complementary structure to the second locking component. 
     
     
         8 . The device of  claim 7 , wherein the first locking component includes a slot structure and the second component includes a complementary protrusion structure. 
     
     
         9 . The device of  claim 6 , wherein the base rim of the end cap is in a press-tit engagement with an inner perimeter of the at least one of the front edge and the back edge of the adsorbing element. 
     
     
         10 . The device of  claim 6 , wherein the end cap further includes an extending rim connecting to the base rim. 
     
     
         11 . The device of  claim 1 , further comprising:
 a first end cap, the second locking component being positioned on he first end cap; and   a second end cap including a fourth locking component,   wherein the adsorbing element comprises the first locking component on the front edge and a third locking component on the back edge, and the first locking component on the front edge of the adsorbing element engages the second locking component of the first end cap and the third locking component on the back edge of the adsorbing element engages the fourth locking component of the second end cap to retain the adsorbing element in the predetermined structure.   
     
     
         12 . The device of  claim 11 , wherein the first locking component has a complementary structure to the second locking component. 
     
     
         13 . The device of  claim 11 , wherein the third locking component has a complementary structure to the fourth locking component. 
     
     
         14 . The device of  claim 1 , further comprising
 an end cap including:
 an outer band wrapping around an exterior surface of the at least one of the front edge and the back edge of the adsorbing element, the second locking component being positioned on the outer band; and 
 an inner band located within an interior surface of the at least one of the front edge and the back edge, the inner hand comprising a third locking component, 
 the first locking component on the at least one of the front edge and the back edge of the adsorbing element engaging the third locking component on the inner band of the end cap and the second locking component on the outer band of the end cap to retain the adsorbing element in the predetermined structure. 
   
     
     
         15 . The device of  claim 14 , wherein the first locking component has a complementary structure to the second locking component. 
     
     
         16 . The device of  claim 14 , wherein the first locking component has the same structure as the third locking component. 
     
     
         17 . The device of  claim 1 , wherein the adsorbing element comprises a substrate and an adsorbent. 
     
     
         18 . The device of  claim 17 , wherein the substrate includes a member selected from the group consisting of paper, plastic, foam, composite, membrane, and combinations thereof. 
     
     
         19 . The device of  claim 17 , wherein the absorbent includes a member selected from the group consisting of activated carbon, charcoal, zeolite, kaolin, titania, ceria, and combinations thereof. 
     
     
         20 . The device of  claim 1 , wherein the adsorbing element comprises an activated carbon sheet. 
     
     
         21 . The device of  claim 1  further comprising a filter for removing particulate matters. 
     
     
         22 . The device of  claim 1  positioned inside an air intake duct of the air intake system. 
     
     
         23 . The device of  claim 1 , further comprising:
 an extending conduit having one end connecting to an air intake ductwork and the other end connecting to an air outlet ductwork,   the adsorbing element positioned in the extending conduit.   
     
     
         24 . An air intake system for an internal combustion engine, comprising the device of Claim  1 . 
     
     
         25 . An emission control device for an air intake system, comprising:
 an adsorbing element including a front edge, a back edge, and side edges extending between the front and back edges, the side edges forming a wall of the adsorbing element and defining an airflow path along a longitudinal axis of the adsorbing element, the adsorbing element being self-formed into a predetermined structure, the adsorbing element comprising a first locking component on at least one of the front edge and the back edge; and   a second locking component having complementary structure to the first locking component and being configured to engage the first locking component.