Segmented Oxidation Catalyst Case for Exhaust Flow Distribution
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Solution Overview
Problem
Conventional engines with a single oxidation catalyst in the exhaust pipe suffer from uneven exhaust gas flow, leading to premature clogging and wasteful replacement of the catalyst, as unclogged portions are discarded along with clogged ones.
Innovation Solution
A catalyst storage case with multiple oxidation catalysts arrayed in a direction intersecting the exhaust passage, ensuring that at least one catalyst remains unclogged, and a baffle plate to uniformly distribute exhaust gas, reducing clogging and allowing only the clogged catalysts to be replaced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single oxidation catalyst is used in the exhaust pipe, then the device complexity is reduced, but the catalyst is prone to partial clogging and requires premature replacement
Solution Approach 1:
The single oxidation catalyst is divided into multiple oxidation catalysts (first oxidation catalyst and second oxidation catalyst) arranged in parallel within the exhaust passage. This segmentation allows the exhaust gas flow to be distributed across multiple catalyst units, reducing the likelihood of complete clogging and enabling selective replacement of only the clogged catalysts.
2Reliability
If multiple oxidation catalysts are arrayed in the exhaust passage, then the reliability is improved by preventing complete clogging, but the device complexity increases
Solution Approach 1:
The exhaust passage is segmented to accommodate multiple oxidation catalysts in parallel, with each catalyst handling a portion of the exhaust gas flow. This segmentation improves reliability by ensuring that if one catalyst becomes clogged, the others continue to function.
Solution Approach 2:
Multiple oxidation catalysts are combined within a single exhaust passage structure, integrating them into a unified system that maintains compact design while achieving improved reliability through parallel catalyst arrangement.
3Loss of substance
If exhaust gas flow becomes uneven within the exhaust pipe, then the catalyst may be partially clogged, but replacing the entire catalyst is wasteful
Solution Approach 1:
The oxidation catalyst system is segmented into multiple independent catalyst units that can be individually replaced. This allows only the clogged catalysts to be replaced while retaining functional catalysts, thereby reducing catalyst waste and operational costs.
Solution Approach 2:
Instead of discarding the entire catalyst assembly when partial clogging occurs, the invention enables selective discarding of only the clogged catalyst units while recovering and retaining the unclogged catalysts for continued use.
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
This configuration reduces waste by allowing only the clogged oxidation catalysts to be replaced, extending their useful life and minimizing unnecessary replacements, while integrating the catalyst storage case and muffler for simplified assembly and reduced component count.
Implementation Method 1
The oxidation catalyst oxidizes oxidizable components contained in exhaust gas discharged from the combustion chamber
Data Source
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AI summary
A catalyst storage case (6) includes a case body (60) having an exhaust passage (60c) ; and first and second oxidation catalysts (61, 62) disposed in the exhaust passage (60c) of the case body (60). The first and second oxidation catalysts (61, 62) are arrayed in a direction intersecting a direction along which the exhaust passage (60c) extends.