Remote DOC Exhaust Layout for Thin Transport Power Housings

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Solution Overview

Problem

Existing exhaust assemblies for diesel prime movers in transport power systems are limited by the size profile of the housing, which restricts the clearance between tractor and transport unit, and fail to efficiently remove pollutants at temperatures below the activation temperature of the diesel oxidation catalyst (DOC).

Innovation Solution

The exhaust assembly includes an extended mid-pipe with a flexible and insulated member that routes exhaust from the diesel prime mover to a diesel oxidation catalyst (DOC) positioned away from the prime mover. This configuration maintains exhaust temperature at or above the activation temperature of the DOC, while the flexible member dampens noise and vibration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of stationary object

If the DOC is positioned close to the prime mover in a stacked arrangement, then the housing depth is reduced, but the exhaust temperature drops below the DOC activation temperature

Engineering Contradiction:

Improvehousing depthVSAvoidexhaust temperature at DOC

Core Design Contradiction:

Length of stationary objectVSTemperature

Solution Approach 1:

The patent transitions from a vertical stacked arrangement (DOC directly above prime mover) to a horizontal extended arrangement (DOC positioned laterally at distance). This dimensional change allows the exhaust to travel through an extended mid-pipe with insulation, maintaining temperature while achieving compact housing depth by utilizing lateral space instead.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The extended mid-pipe with insulation acts as an intermediary element between the prime mover exhaust outlet and the DOC inlet. This intermediary component preserves exhaust temperature during transport by providing thermal insulation, enabling the DOC to receive sufficiently heated exhaust even when positioned at a distance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the DOC is positioned away from the prime mover using an extended mid-pipe, then the exhaust temperature is maintained above activation temperature, but the housing depth increases

Engineering Contradiction:

Improveexhaust temperature at DOCVSAvoidhousing depth

Core Design Contradiction:

TemperatureVSLength of stationary object

Solution Approach 1:

The patent employs a flexible extended mid-pipe that can dynamically adapt its routing configuration. This flexibility allows the mid-pipe to navigate around other components and optimize the DOC positioning within the housing, achieving temperature maintenance while minimizing the impact on housing depth through adaptable routing rather than rigid fixed-positioning.

Inventive Principle:

Principle #15Dynamics

3Temperature

If a rigid extended mid-pipe is used to position the DOC remotely, then the exhaust temperature is maintained, but noise and vibration increase

Engineering Contradiction:

Improveexhaust temperature at DOCVSAvoidnoise and vibration

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent specifies using a flexible extended mid-pipe rather than a rigid one. This flexible construction inherently dampens mechanical vibrations and reduces noise transmission from the prime mover to the DOC and housing, while still providing sufficient structural integrity to maintain exhaust flow and thermal insulation properties.

Inventive Principle:

Principle #30Flexible shells and thin films

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 solution effectively reduces the size profile of the housing, allowing for a thinner design that fits within limited clearance spaces, and ensures efficient pollutant removal by maintaining the exhaust temperature above the DOC's activation temperature.

Implementation Method 1

The insulated member is configured to maintain a temperature of the exhaust to at or above an activation temperature of the DOC

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

The flexible member is configured to dampen noise and vibration created by the prime mover during operation

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 3

The DOC is configured to operate at a temperature at or above an activation temperature for removing pollutants from exhaust flowing through the DOC

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

diesel oxidation catalyst (DOC) to remove at least some of the pollutants in the exhaust

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentEP4520929A1Remote diesel oxidation catalyst for a prime mover of a transport power system

Publication Date: 2025.03.12 THERMO KING CORP

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Figure 1C

AI summary

A transport power system for generating power is provided. The transport power system includes an extended mid-pipe having a flexible member and an insulated member that is connected to the flexible member. The flexible member is coupled to an exhaust manifold disposed on a diesel prime mover that is configured to generate exhaust. The extended mid-pipe is configured to receive the exhaust from the exhaust manifold. The diesel oxidation catalyst (DOC) is coupled to the insulated member. The transport power system also includes a housing containing the DOC and the diesel prime mover. The DOC is positioned away from the diesel prime mover such that the DOC is configured to be unstacked in a depth direction of the housing. The insulated member is configured to maintain a temperature of the exhaust to at or above an activation temperature of the DOC.