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The 30-year-old played out of his skin and saved three match points, only to endure the agony of losing it in the end, as Chou emerged victorious in a pulsating contest.
This is India' maiden medal in men's doubles at the Worlds.
World No. 7 Satwiksairaj and Chirag dished out a gritty performance to outwit local favourites and defending champions Takuro Hoki and Yugo Kobayashi.
The two Indian men's doubles pair of Dhruv Kapila and M R Arjun and Satwiksairaj Rankireddy and Chirag Shetty also moved into the quarterfinals.
Sen defeated Spain's Luis Penalver 21-17 21-10 in the BWF World Championships in Tokyo on Wednesday.
The women's doubles pair of Treesa Jolly and Gayatri Gopichand also made a winning start.
Ashwini Ponnappa and N Sikki Reddy progressed to the women's doubles second round.
As India finished fourth on the podium with an overall medal tally of 61, Malayali athletes accounted for six of them.
Kiran George gave top seed Chen Tien Chou of Chinese Taipei a scare before losing 21-23, 21-16, 7-21 in the second round of the BWF World Tour Super 300 event.
Sindhu beat China's Wang Zhi Yi in the final.