# US 11,111,838 B2 · Marine engine exhaust system having secondary air injection

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- Number: US 11,111,838 B2
- Document ID: US11111838B2
- Status: Granted
- Kind: B2
- Application number: 16/744,372
- Filed: 2020-01-16
- Published: 2020-08-13
- Granted: 2021-09-07
- Earliest claimed: 2019-02-13
- Assignees: Indmar Products Company Inc.
- Applicants: Indmar Products Company Inc.
- Inventors: Richard J. Waggoner; Jason C. Stimmel; Jason Vetzel; Derrick W. Lloyd; Timothy G. Anderson
- Web page: https://patentgrep.com/patent/US11111838B2

## CPC

- F01N 3/32: using air pump (using jet air pumps F01N3/34; pumps in general F04)
- F01D 25/14: Casings modified therefor (double casings F01D25/26)
- F01N 3/05: by means of air, e.g. by mixing exhaust with air (silencers working by addition of air to exhaust F01N1/14; arrangements for the supply of additional air for the thermal or catalytic conversion of noxious components of exhaust F01N3/30)
- F01N 3/20: specially adapted for catalytic conversion (F01N3/22 takes precedence)
- F01N 3/222: {using electric valves only}
- F01N 3/30: Arrangements for supply of additional air (control, e.g. using by-passes or variable air pump drives, F01N3/22)
- F01N 11/007: {the diagnostic devices measuring oxygen or air concentration downstream of the exhaust apparatus}
- F02B 37/168: {into the exhaust conduit (F02B37/166 takes precedence)}
- F02C 7/24: Heat or noise insulation (air intakes having provisions for noise suppression F02C7/045; turbine exhaust heads, chambers, or the like F01D25/30; silencing nozzles of jet-propulsion plants F02K1/00)
- F01N 3/323: {Electrically driven air pumps}
- F01N 2560/025: for measuring or detecting O2, e.g. lambda sensors
- F01N 2590/021: for outboard engines
- F05D 2220/40: in turbochargers
- F05D 2260/231: Preventing heat transfer
- Y02T 10/12: Improving ICE efficiencies
- F01N: GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL-COMBUSTION ENGINES (arrangements in connection with gas exhaust of propulsion units in vehicles B60K13/00; combustion-air intake silencers specially adapted for, or arranged on, internal-combustion engines F02M35/00; protecting against, or damping, noise in general G10K11/16)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F02B: INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL (gas-turbine plants F02C; hot-gas or combustion-product positive-displacement engine plants F02G)
- F02C: GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS (construction of turbines F01D; jet-propulsion plants F02K; construction of compressors or fans F04; generating combustion products of high pressure or high velocity F23R; using gas turbines in compression refrigeration plants F25B11/00)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

An air intake and exhaust system for a marine engine having an intake manifold and an exhaust manifold includes an air compressor configured to compress ambient air into compressed air and a catalytic converter assembly configured to convert pollutants in an exhaust gas stream received from the exhaust manifold. The air compressor is configured to be fluidly coupled to the intake manifold of the engine for directing at least a first portion of the compressed air to the intake manifold of the engine. The air compressor is also selectively fluidly coupled to the catalytic converter assembly for selectively directing a second portion of the compressed air into the exhaust gas stream at a secondary air injection location at or upstream of the catalytic converter assembly.

## Claims

### Claim 1

An assembly for a marine craft comprising:
a marine engine having an intake manifold and an exhaust manifold;
an air compressor configured to compress ambient air into compressed air; and
a catalytic converter assembly including a catalyst element, the catalytic converter assembly being configured to convert pollutants in an exhaust gas stream received from the exhaust manifold of the engine,
a controller,
wherein the air compressor is configured to be fluidly coupled to the intake manifold of the engine for directing at least a first portion of the compressed air to the intake manifold of the engine, and wherein the air compressor is selectively fluidly coupled to the catalytic converter assembly for selectively directing a second portion of the compressed air into the exhaust gas stream at a secondary air injection location at or upstream from the catalytic converter assembly,
a first oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream upstream from the secondary air injection location,
a second oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream downstream from the catalytic converter assembly, wherein the controller compares oxygen levels detected by the second oxygen sensor to oxygen levels taken by the first oxygen sensor to determine whether the catalyst element is effectively removing toxic pollutants from the exhaust gas stream.

### Claim 2 (depends on 1)

The assembly for a marine craft of claim 1, further comprising:
a turbine configured to extract energy from the exhaust stream and operatively coupled to the air compressor to transfer the extracted energy to the ambient air for compressing the ambient air into compressed air.

### Claim 3 (depends on 1)

The assembly for a marine craft of claim 1, further comprising:
an intercooler fluidly coupled to the air compressor and configured to increase the density of the compressed air.

### Claim 4 (depends on 1)

The assembly for a marine craft of claim 1, further comprising:
a valve positioned between the air compressor and the catalytic converter assembly, wherein the valve is movable between at least one open position and a closed position, and wherein the air compressor is in fluid communication with the catalytic converter assembly when the valve is in the at least one open position.

### Claim 5 (depends on 4)

The assembly for a marine craft of claim 4, wherein the controller is in operative communication with the valve for sending at least one signal to the valve to move the valve to the at least one open position or to the closed position.

### Claim 6 (depends on 3)

The assembly for a marine craft of claim 3, wherein the intercooler has an intercooler outlet conduit in fluid communication with the intake manifold, the intercooler outlet conduit having a secondary air outlet, the secondary air outlet being joined to a secondary air injection conduit, the secondary air injection conduit bypassing the marine engine and terminating in a secondary air inlet of an exhaust conduit.

### Claim 7 (depends on 5)

The assembly for a marine craft of claim 5, wherein the controller is configured to send the at least one signal to the valve in response to the detected oxygen level.

### Claim 8 (depends on 4)

The assembly for a marine craft of claim 4, wherein the at least one open position includes a plurality of open positions.

### Claim 9 (depends on 1)

The assembly for a marine craft of claim 1, wherein the marine engine has two banks of cylinders.

### Claim 10 (depends on 1)

A marine craft comprising the assembly for a marine craft of claim 1.

### Claim 11

An assembly for a marine craft comprising:
a marine engine having an intake manifold and an exhaust manifold;
an air compressor configured to compress ambient air into compressed air; and
a catalytic converter assembly including a catalyst element positioned downstream of and in fluid communication with an exhaust conduit, the catalytic converter assembly being configured to convert pollutants in an exhaust gas stream received from the exhaust manifold of the engine,
a controller,
a first oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream upstream from the secondary air inlet of the exhaust conduit,
a second oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream downstream from the catalytic converter assembly, wherein the controller compares oxygen levels detected by the second oxygen sensor to oxygen levels taken by the first oxygen sensor to determine whether the catalyst element is effectively removing toxic pollutants from the exhaust gas stream,
wherein the air compressor is fluidly coupled to an intercooler having an intercooler outlet conduit in fluid communication with the intake manifold of the engine for directing at least a first portion of the compressed air to the intake manifold of the engine, and wherein the intercooler outlet conduit has a secondary air outlet, the secondary air outlet being joined to a secondary air injection conduit, the secondary air injection conduit bypassing the marine engine and terminating in a secondary air inlet of the exhaust conduit for selectively directing a second portion of the compressed air into the exhaust gas stream to the secondary air inlet of the exhaust conduit upstream from the catalytic converter assembly.

### Claim 12 (depends on 11)

The assembly of claim 11, further comprising:
a turbine configured to extract energy from the exhaust stream and operatively coupled to the air compressor to transfer the extracted energy to the ambient air for compressing the ambient air into compressed air.

### Claim 13 (depends on 11)

The assembly of claim 11, further comprising:
a valve positioned in-line with the secondary air injection conduit, wherein the valve is movable between at least one open position and a closed position, and wherein the air compressor is in fluid communication with the catalytic converter assembly when the valve is in the at least one open position.

### Claim 14 (depends on 13)

The assembly of claim 13,
wherein the controller is in operative communication with the valve for sending at least one signal to the valve to move to the at least one open position or to the closed position.

### Claim 15 (depends on 12)

The assembly of claim 12, wherein the turbine is positioned downstream of and in fluid communication with the exhaust manifold.

### Claim 16

An assembly for a marine craft comprising:
a marine engine having an intake manifold and an exhaust manifold;
a turbocharger comprising a turbine positioned downstream and in fluid communication with the exhaust manifold for receiving exhaust gases expelled therefrom, the turbocharger further comprising an air compressor configured to compress ambient air into compressed air,
a catalytic converter assembly positioned downstream of and in fluid communication with an exhaust conduit, the catalytic converter assembly being configured to convert pollutants in an exhaust gas stream received from the exhaust manifold of the engine,
an intercooler fluidly coupled to the air compressor and having an intercooler outlet conduit in fluid communication with the intake manifold of the engine for directing at least a first portion of the compressed air to the intake manifold of the engine,
wherein the intercooler outlet conduit has a secondary air outlet downstream of the intercooler, the secondary air outlet being joined to a secondary air injection conduit, the secondary air injection conduit bypassing the marine engine and terminating in a secondary air inlet of the exhaust conduit for selectively directing a second portion of the compressed air into the exhaust gas stream at or upstream from the catalytic converter assembly,
a valve positioned in-line with the secondary air injection conduit, the valve being movable between at least one open position and a closed position by a controller, wherein secondary air flows through the secondary air injection conduit when the valve is in the at least one open position and does not flow through the secondary air injection conduit when the valve is in the closed position,
a first oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream upstream from the secondary air inlet of the exhaust conduit, and
a second oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream downstream from the catalytic converter assembly, wherein the controller compares oxygen levels detected by the second oxygen sensor to oxygen levels taken by the first oxygen sensor to determine whether the catalytic converter assembly is effectively removing toxic pollutants from the exhaust gas stream.

### Claim 17

An assembly for a marine craft comprising:
a marine engine having an intake manifold and an exhaust manifold;
a turbocharger comprising a turbine positioned downstream and in fluid communication with the exhaust manifold for receiving exhaust gases expelled therefrom, the turbocharger further comprising an air compressor configured to compress ambient air into compressed air,
a catalytic converter assembly positioned downstream of and in fluid communication with an exhaust conduit, the catalytic converter assembly being configured to convert pollutants in an exhaust gas stream received from the exhaust manifold of the engine,
an intercooler fluidly coupled to the air compressor and having an intercooler outlet conduit in fluid communication with the intake manifold of the engine for directing at least a first portion of the compressed air to the intake manifold of the engine,
wherein the intercooler outlet conduit has a secondary air outlet downstream of the intercooler, the secondary air outlet being joined to a secondary air injection conduit, the secondary air injection conduit bypassing the marine engine and terminating in a secondary air inlet of the exhaust conduit for selectively directing a second portion of the compressed air into the exhaust gas stream at or upstream from the catalytic converter assembly,
a valve positioned in-line with the secondary air injection conduit, the valve being movable between at least one open position and a closed position by a controller, wherein secondary air flows through the secondary air injection conduit when the valve is in the at least one open position and does not flow through the secondary air injection conduit when the valve is in the closed position,
a first oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream upstream from the secondary air inlet of the exhaust conduit, and
a second oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream downstream from the catalytic converter assembly, wherein the controller compares oxygen levels detected by the second oxygen sensor to oxygen levels taken by the first oxygen sensor to determine whether to open or close the valve.

### Claim 18

An assembly for a marine craft comprising:
a marine engine having an intake manifold and an exhaust manifold;
an exhaust conduit in fluid communication with the exhaust manifold,
a catalytic converter assembly positioned downstream of and in fluid communication with the exhaust conduit, the catalytic converter assembly being configured to convert pollutants in an exhaust gas stream received from the exhaust manifold of the engine,
an intercooler having an intercooler outlet conduit in fluid communication with the intake manifold of the engine for directing at least a first portion of compressed air to the intake manifold of the engine,
wherein the intercooler outlet conduit has a secondary air outlet downstream of the intercooler, the secondary air outlet being joined to a secondary air injection conduit, the secondary air injection conduit bypassing the marine engine and terminating in a secondary air inlet of the exhaust conduit for selectively directing a second portion of compressed air into the exhaust gas stream upstream from the catalytic converter assembly, and
a valve positioned in-line with the secondary air injection conduit, the valve being movable between at least one open position and a closed position by a controller, wherein secondary air flows through the secondary air injection conduit when the valve is in the at least one open position; and
a first oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream upstream from the secondary air inlet of the exhaust conduit,
a second oxygen sensor in operative communication with the controller and configured to detect an oxygen level of the exhaust gas stream downstream from the catalytic converter assembly, wherein the controller compares oxygen levels detected by the second oxygen sensor to oxygen levels taken by the first oxygen sensor to determine whether to open or close the valve.