Exhaust Purification Cooling Layout for Fast Catalyst Activation

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Solution Overview

Problem

Existing exhaust gas purification devices in internal combustion engines face degradation due to high temperature exposure, leading to reduced purification performance and difficulty in meeting stringent emissions regulations.

Innovation Solution

Integrating a cooler within the exhaust flow path of the internal combustion engine to cool the purification device, which is positioned near the combustion chamber, thereby maintaining purification performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the purification device is arranged away from the internal combustion engine, then the catalyst has time to reach activation temperature, but the exhaust purification performance is not fully achieved immediately after start

Engineering Contradiction:

Improvecatalyst activation temperatureVSAvoidtime to achieve purification performance

Core Design Contradiction:

TemperatureVSLoss of time

Solution Approach 1:

The exhaust system is divided into multiple flow paths with purification devices positioned at different locations. Some purification devices are placed near the combustion chamber for immediate activation, while others are positioned downstream to handle exhaust at different temperature stages, allowing the system to address both rapid activation and sustained purification needs

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from a single linear exhaust path to a multi-dimensional exhaust flow path structure with multiple branches and convergence points. This allows purification devices to be positioned in three-dimensional space along the exhaust flow, enabling simultaneous placement of devices at different thermal environments and distances from the combustion chamber

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Loss of time

If the catalyst section is arranged at the exhaust port of the combustion chamber, then exhaust purification performance is achieved quickly, but the catalyst section is exposed to high temperature exhaust gas continuously

Engineering Contradiction:

Improvetime to achieve purification performanceVSAvoidpurification performance degradation

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The exhaust system is segmented into multiple flow paths with purification devices distributed along different routes. This segmentation allows the exhaust flow to be divided, reducing the thermal load on individual purification devices while maintaining overall purification effectiveness through the combined output of multiple devices positioned at different thermal zones

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different purification devices are positioned in different locations along the exhaust flow path, creating local variations in thermal exposure. Devices near the combustion chamber handle high-temperature exhaust briefly, while devices in downstream positions handle cooler exhaust, with each location optimized for its specific thermal conditions

Inventive Principle:

Principle #3Local quality

3Speed

If the purification device is positioned near the combustion chamber, then rapid activation is achieved, but catalyst metal aggregates and purification performance degrades

Engineering Contradiction:

Improveactivation speedVSAvoidpurification performance stability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The purification function is segmented across multiple devices positioned at different locations. Fast-activating devices are placed near the combustion chamber to provide immediate purification, while additional devices are positioned downstream to provide sustained purification with lower thermal exposure, collectively maintaining reliable performance over time

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system performs preliminary purification action through devices positioned near the combustion chamber that activate quickly, while downstream devices prepare to take over as the exhaust cools, creating a staged purification approach that maintains performance reliability throughout operation

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cooler reduces degradation of the purification device, allowing it to reach activation temperature faster, enhancing purification efficiency and compliance with emissions standards without additional heating devices or increased costs.

Implementation Method 1

a cooler configured to cool the at least one purification device

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12601285B2Internal combustion engine and purification device

Publication Date: 2026.04.14 FUTABA IND CO LTD

AI summary

An internal combustion engine includes at least one combustion chamber, a main body, at least one purification device, and a cooler. The main body includes therein the at least one combustion chamber, and an exhaust flow path configured to allow exhaust gas flowing out of the at least one combustion chamber to flow down. The at least one purification device is arranged in the exhaust flow path of the main body. The cooler is configured to cool the at least one purification device. Each of the at least one purification device includes a purification member and a case. The purification member is configured to purify the exhaust gas. The case contains the purification member.