Catalyst substrate heater with improved heating distribution

Abstract

The present disclosure relates to resistive heater bodies having a honeycomb structure and one or more current directing features, and systems having such resistive heater bodies. The honeycomb heater body and system of the present disclosure are particularly useful for reducing cold start emissions of gasoline and diesel powered engines. More specifically, the resistive heater body of the present disclosure provides a current directing feature, enabling improved heating performance of a downstream catalyst-containing substrate.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority under 35 U.S.C. §119 to U.S. Provisional Application Serial No. 63 / 438,308, filed on January 11, 2023, the contents of which are relied upon and incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates generally to resistive heater bodies for fluid aftertreatment systems and, more particularly, to resistive heater bodies having one or more current directing features. Background Art

[0004] In modern gasoline and diesel-powered engines, exhaust aftertreatment systems are used to reduce emissions generated during engine operation, including but not limited to particulate matter, volatile organic compounds, nitrogen oxides, carbon monoxide, carbon dioxide, and sulfur dioxide. In some aftertreatment systems, a catalyst-containing substrate is used to capture one or more of these undesirable emissions. However, cold-start emissions (i.e., emissions generated within the first 20 to 60 seconds after ignition) remain the most toxic portion of the engine's operating cycle. During this period, the catalyst-containing substrate cannot reach full efficiency until the engine exhaust heats the catalyst to a temperature that initiates the catalytic reaction. Summary of the Invention

[0005] According to one embodiment of the present disclosure, a resistive heater body is provided. The resistive heater body comprises: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed by a heater body composition comprising a conductive material; a plurality of slots extending from an outer periphery of the resistive heater body into the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form the plurality of cell channels in a serpentine pattern from a first side of the resistive heater body to a second side of the resistive heater body; and one or more current directing features, each current directing feature being located near an end of at least one of the plurality of slots, wherein each current directing feature comprises: (i) a first linear portion extending in a first direction perpendicular to the slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) an intermediate portion having one or more modified cell channels connecting the first linear portion and the second linear portion.

[0006] In one aspect, the plurality of bore channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0007] In one aspect, the slot extends axially from a first end surface of the resistive heater body to a second end surface of the resistive heater body.

[0008] In one aspect, the first and second linear portions of the one or more current directing features include thickened hole walls having a thickness greater than a thickness of an intersecting hole wall.

[0009] In one aspect, the intermediate portion of one or more current directing features includes one or more rounded and / or chamfered hole walls.

[0010] In one aspect, the first and second linear portions of the one or more current directing features include thickened bore walls extending in an axial direction through the resistive heater body from a first end face to a second end face of the resistive heater body.

[0011] In one aspect, the one or more modified bore walls of the intermediate portion of the one or more current directing features extend in an axial direction through the resistive heater body from a first end face to a second end face of the resistive heater body.

[0012] In one aspect, each of the plurality of slots has a width equal to one cell channel.

[0013] In one aspect, a center of the intermediate portion of each of the one or more current directing features is one aperture channel away from an end of at least one of the plurality of slots.

[0014] In one aspect, a terminal end of each of the plurality of slots is spaced at least five aperture channels from the outer peripheral region of the resistive heater body.

[0015] In one aspect, each end of one or more of the plurality of slots is separated from the outer peripheral region of the resistive heater body by at most two bore channels.

[0016] In one aspect, one or more slots of the plurality of slots extend from an outer periphery of the resistive heater body into the resistive heater body for a first length in a first direction and for at least a second length in a second direction.

[0017] According to another embodiment of the present disclosure, a resistive heater body is provided, comprising: a plurality of pore channels formed by intersecting pore walls, wherein the intersecting pore walls are formed by a heater body composition comprising a conductive material; a plurality of slots extending from an outer periphery of the resistive heater body into the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form a serpentine pattern of the plurality of pore channels from a first side of the resistive heater body to a second side of the resistive heater body; one or more current directing features, each current directing feature being near an end of at least one of the plurality of slots, wherein each current directing feature comprises a continuous length of modified pore walls corresponding to an array of partially filled pore channels; wherein one or more of the plurality of slots have corresponding ends that are separated from the outer periphery region of the resistive heater body by at most two pore channels.

[0018] In one aspect, the plurality of bore channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0019] In one aspect, the slot extends axially from a first end surface of the resistive heater body to a second end surface of the resistive heater body.

[0020] In one aspect, at least a portion of one or more of the current directing features follows a contour of the outer peripheral region.

[0021] In one aspect, the one or more current directing features further comprise one or more completely filled pore channels along a continuous length of the current directing feature.

[0022] In one aspect, the resistive heater body further comprises one or more regions of completely filled aperture channels, each region being adjacent to an outer perimeter region of the resistive heater body and each region being separated from the one or more current directing features by at least one aperture channel.

[0023] In one aspect, one or more slots of the plurality of slots extend from an outer periphery of the resistive heater body into the resistive heater body for a first length in a first direction and for at least a second length in a second direction.

[0024] According to another embodiment of the present disclosure, a fluid treatment system is provided. The fluid treatment system includes: a catalyst-containing substrate in fluid communication with a resistive heater body, the resistive heater body being positioned upstream of the catalyst-containing substrate; wherein the resistive heater body includes: a plurality of pore channels formed by intersecting pore walls, wherein the intersecting pore walls are formed by a heater body composition including a conductive material; a plurality of slots extending from an outer periphery of the resistive heater body into the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form the plurality of pore channels in a serpentine pattern from a first side of the resistive heater body to a second side of the resistive heater body; and one or more current directing features, each current directing feature being located near an end of at least one of the plurality of slots, wherein each current directing feature includes: (i) a first linear portion extending in a first direction perpendicular to the slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) an intermediate portion having one or more modified pore channels connecting the first linear portion and the second linear portion.

[0025] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiments described hereinafter. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In the drawings, like reference numerals generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0027] Figure 1 is a diagram illustrating a resistive heater body according to aspects of the present disclosure.

[0028] Figure 2A are diagrams illustrating certain improved well channel arrangements according to aspects of the present disclosure.

[0029] Figure 2B are diagrams illustrating other improved hole channel arrangements according to aspects of the present disclosure.

[0030] Figure 3 is a diagram illustrating a first current directing feature at the end of a slot of a resistive heater body according to aspects of the present disclosure.

[0031] Figure 4 is a diagram illustrating a second current directing feature at the end of a slot of a resistive heater body according to aspects of the present disclosure.

[0032] Figure 5 is a diagram illustrating a third current directing feature at the end of a slot of a resistive heater body according to aspects of the present disclosure.

[0033] Figure 6 is a graph illustrating heating performance of resistive heaters with comparative current directing features according to aspects of the present disclosure.

[0034] Figure 7 is a graph illustrating changes in heating performance of a resistive heater body having a first current directing characteristic relative to a comparative current directing characteristic according to aspects of the present disclosure.

[0035] Figure 8 is a graph illustrating changes in heating performance of a resistive heater body having a second current directing characteristic relative to a comparative current directing characteristic according to aspects of the present disclosure.

[0036] Figure 9 is a graph illustrating changes in heating performance of a resistive heater body having a third current directing characteristic relative to a comparative current directing characteristic according to aspects of the present disclosure.

[0037] Figure 10A is a diagram illustrating a first combination of current directing features and slot design for a resistive heater body according to aspects of the present disclosure.

[0038] Figure 10B is a graph illustrating heating performance of a resistive heater body having a first combination of current directing features and slot design according to aspects of the present disclosure.

[0039] Figure 11A is a diagram illustrating a second combination of current directing features and slot design for a resistive heater body according to aspects of the present disclosure.

[0040] Figure 11B is a graph illustrating heating performance of a resistive heater body having a second combination of current directing features and slot design, according to aspects of the present disclosure.

[0041] Figure 12A is a diagram illustrating a third combination of current directing features and slot designs for a resistive heater body according to aspects of the present disclosure.

[0042] Figure 12B is a graph illustrating heating performance of a resistive heater body having a third combination of current directing features and slot design, according to aspects of the present disclosure.

[0043] Figure 13A is a diagram illustrating a fourth combination of current directing features and slot designs for a resistive heater body according to aspects of the present disclosure.

[0044] Figure 13B is a graph illustrating heating performance of a resistive heater body having a fourth combination of current directing features and slot design, according to aspects of the present disclosure.

[0045] Figure 14A is a diagram illustrating a fifth combination of current directing features and slot designs for a resistive heater body according to aspects of the present disclosure.

[0046] Figure 14B is a graph illustrating heating performance of a resistive heater body having a fifth combination of current directing features and slot design, according to aspects of the present disclosure.

[0047] Figure 15A is a diagram illustrating a sixth combination of current directing features and slot designs for a resistive heater body according to aspects of the present disclosure.

[0048] Figure 15B is a graph illustrating heating performance of a resistive heater body having a sixth combination of current directing features and slot design, according to aspects of the present disclosure.

[0049] Figure 16A is a diagram illustrating a seventh combination of current directing features and slot designs for a resistive heater body according to aspects of the present disclosure.

[0050] Figure 16B is a graph illustrating heating performance of a resistive heater body having a seventh combination of current directing features and slot design, according to aspects of the present disclosure.

[0051] Figure 17 is a cross-sectional side view illustration of a fluid treatment system including a catalyst substrate and a resistive heater assembly according to aspects of the present disclosure.

[0052] Figure 18A is a graph illustrating the heating performance of a honeycomb matrix downstream of a resistive heater body having a baseline fillet pattern, according to aspects of the present disclosure.

[0053] Figure 18B is a graph illustrating heating performance of a honeycomb matrix downstream of a resistive heater body having a fourth combination of current directing features and slot design, in accordance with aspects of the present disclosure.

[0054] Figure 18C is a graph illustrating heating performance of a honeycomb matrix downstream of a resistive heater body having a fifth combination of current directing features and slot design, in accordance with aspects of the present disclosure.

[0055] Figure 18D is a graph illustrating heating performance of a honeycomb matrix downstream of a resistive heater body having a sixth combination of current directing features and slot design, in accordance with aspects of the present disclosure. DETAILED DESCRIPTION

[0056] One approach to reducing undesirable emissions from gasoline and diesel-powered engines is to use substrates and / or filters in exhaust aftertreatment systems. For example, a catalyst-containing substrate can be deployed within a fluid treatment system to receive exhaust from the engine and then release the exhaust into the environment. Chemical reactions within the catalyst-containing substrate capture certain undesirable components of the exhaust. However, even with a fluid treatment system containing a catalyst-containing substrate, cold-start emissions can generate significant amounts of undesirable emissions during a typical engine operating cycle.

[0057] To address the issue of cold start emissions, the present disclosure relates to a resistive heater body having one or more current directing features, and is particularly suitable for use in fluid handling systems to reduce the light-off time of a catalyst in a catalyst-containing substrate of the fluid handling system. More specifically, the resistive heater body must allow current to flow through the heater body in a manner that effectively heats adjacent fluid streams (e.g., exhaust gas, etc.). However, depending on the flow of current, conventional resistive heater designs may result in cold spots where the heating efficiency of the resistive heater body is not as high as in other areas of the resistive heater body. Accordingly, the present disclosure relates to a heater body including one or more current directing features that addresses these and other shortcomings.

[0058] Steering Figure 1 , shows a resistive heater body 100 for a fluid treatment system according to aspects of the present disclosure. As shown, the resistive heater body 100 includes a plurality of bore channels 102 formed by an array of intersecting bore walls 104, 104'. The resistive heater body 100 may include an outer skin 128 that provides additional structural support and is formed at an outer periphery 118 of the resistive heater body 100. The plurality of bore channels 102 may be parallel to each other and extend through the body 100 in an axial direction between opposite end faces of the resistive heater body 100 (e.g., from a first end face to a second end face of the resistive heater body 100).

[0059] exist Figure 1 In the example of , the cell channels 102 generally have a rectangular cross-sectional shape. However, in embodiments, one or more of the cell channels 102 may have other regular or irregular cross-sectional shapes, including but not limited to triangles, heptagons, hexagons, octagons, trapezoids, diamonds, circles, ellipses, other polygonal shapes, and / or combinations thereof. In particular embodiments, the corners of the cell channels 102 may be rounded or filleted, as discussed in more detail below. In embodiments, the perimeter shape of the resistive heater body 100 may be circular, such as Figure 1However, the perimeter of the resistive heater body 100 may alternatively be rectangular, triangular, heptagonal, hexagonal, octagonal, trapezoidal, rhombus-shaped, circular, elliptical, or another polygonal shape. In embodiments, these arrangements of cell channels 102 and cell walls 104, 104' may be referred to as a honeycomb matrix or honeycomb body.

[0060] In some embodiments, the intersecting hole walls 104, 104' may be formed from a batch mixture comprising a conductive material. For example, the batch mixture may include a metal and / or a metal alloy. In certain embodiments, the batch mixture may contain at least one of iron (Fe), chromium (Cr), aluminum (Al), nickel (Ni), and the like.

[0061] In another embodiment, the intersecting pore walls 104, 104' may be formed from a composite material comprising: a first phase of a porous material defining internal interconnected pores; and a second phase of a conductive material at least partially filling the internal interconnected pores of the first phase. In some embodiments, the material of the first phase is a porous ceramic, a porous glass ceramic, and / or a porous glass material. In specific embodiments, the material of the first phase comprises cordierite, aluminum titanate, aluminum oxide, silicon carbide, silicon nitride, mullite, sapphire, spinel, calcium aluminate, zirconium phosphate, β-spodumene, β-eucryptite (LiAlSiO4), cordierite-glass ceramic, fused silica, doped fused silica, and / or the like, including combinations thereof. In some embodiments, the conductive material of the second phase comprises metal and / or metal alloy particles, such as molybdenum, molybdenum-containing compounds, molybdenum disilicide (MoSi2), silicon carbide (SiC) doped with boron (B), aluminum (Al), or nitrogen (N), and the like.

[0062] Advantageously, the second phase can form a continuous, three-dimensional, interconnected conductive phase that provides a continuous, three-dimensional conductive path laterally across the resistive heater body 100 (in a direction 108 perpendicular to the axial direction) (e.g., between a first side 112 and an opposing second side 116 of the resistive heater body 100).

[0063] In embodiments, the resistive heater body 100 may have a defined channel density measured as an average number of pores per square inch (cpsi). In some embodiments, the channel density may be approximately 100 cpsi (31 pores / cm 2 ) to about 600 cpsi (186 pores / cm 2 ), including about 100 cpsi to about 200 cpsi, about 200 cpsi to about 300 cpsi, about 300 cpsi to about 400 cpsi, about 400 cpsi to about 500 cpsi, about 500 cpsi to about 600 cpsi, and any combination of endpoints thereof.

[0064] In an embodiment, the aperture walls 104, 104' of the resistive heater body 100 may have a defined transverse wall thickness T w , the transverse wall thickness T w From about 2 mils to about 14 mils, including about 2 mils to about 3 mils, about 3 mils to about 4 mils, about 4 mils to about 5 mils, about 5 mils to about 6 mils, about 6 mils to about 7 mils, about 7 mils to about 8 mils, about 8 mils to about 9 mils, about 9 mils to about 10 mils, about 10 mils to about 11 mils, about 11 mils to about 12 mils, about 12 mils to about 13 mils, about 13 mils to about 14 mils, and any combination of endpoints thereof.

[0065] In embodiments, the average size of the pore channels 102 of the resistive heater body 100 may be from about 1.0 mm to about 2.5 mm, including from about 1.0 mm to about 1.5 mm, from about 1.5 mm to about 2.0 mm, from about 2.0 mm to about 2.5 mm, and any combination thereof.

[0066] Thus, the resistive heater body 100 can be formed of intersecting aperture walls 104, 104' that enable the passage of electrical current, such that the resistive heater body 100 is conductive between the respective opposing sides 112, 116. In embodiments, one or more slots 106 can be formed within the resistive heater body 100 to increase the length of the conductive path between the opposing sides 112, 116.

[0067] For example, Figure 1 As shown, the resistive heater body 100 includes a plurality of slots 106 extending transversely into the resistive heater body 100 from alternating directions along a direction 108 of the resistive heater body 100. That is, each slot 106 may extend from an outer periphery 118 of the resistive heater body 100 through the intersecting bore walls 104, 104' until reaching a terminal end 107 located within the interior of the resistive heater body 100. Thus, the plurality of slots 106 may define a serpentine conductive path from a first side 112 of the resistive heater body 100 to a second side 116 of the resistive heater body 100.

[0068] In some embodiments, each of the slots 106 may extend axially from a first end face of the resistive heater body 100 to a second end face of the resistive heater body 100. In embodiments, the slot width of each of the slots 106 may be from about 1.0 mm to about 2.5 mm, including from about 1.0 mm to about 1.5 mm, from about 1.5 mm to about 2.0 mm, from about 2.0 mm to about 2.5 mm, and any combination thereof, or about the size of one aperture channel 102. In particular embodiments, the end 107 of one or more slots 106 may be spaced a predetermined distance from the outer periphery 118 of the resistive heater body 100 (e.g., at least five aperture channels, at most two aperture channels, etc.). In some embodiments, as discussed in more detail below, the end 107 of one or more slots 106 is spaced a predetermined distance from the covered portion of the resistive heater body 100. Furthermore, while the slots 106 are shown as having a straight path from the outer periphery 118 of the resistive heater body 100 to the corresponding end 107, it should be understood that the slots 106 may have other shapes or trajectories (e.g., Figure 16A and 16B shown).

[0069] In some embodiments, the plurality of slots 106 may be air gaps or may be completely or partially filled with an electrically insulating material, such as alumina. In certain embodiments, the insulating material may have a coefficient of thermal expansion substantially equal to the coefficient of thermal expansion of the combination of the intersecting hole walls 104, 104'.

[0070] In embodiments, the electrical conductivity along the conductive path of the resistive heater body 100 of the present disclosure may be at least about 300 S / cm, including at least about 500 S / cm, at least about 1,000 S / cm, and / or at least about 1,500 S / cm. In particular embodiments, the electrical conductivity along the conductive path of the resistive heater body 100 may be from about 300 S / cm to about 2,500 S / cm, including from about 500 S / cm to about 2,000 S / cm, from about 1,000 S / cm to about 1,500 S / cm, and / or any combination thereof.

[0071] According to the present disclosure, the resistive heater bodies disclosed herein (e.g., resistive heater body 100) include one or more current directing features near the end of a corresponding slot (e.g., end 107 of slot 106). In embodiments, one or more of the plurality of slots 106 of the resistive heater body 100 may have a corresponding current directing feature. In some embodiments, each of the plurality of slots 106 of the resistive heater body 100 may have a corresponding current directing feature. In embodiments, the current directing features described herein may extend the entire length of the resistive heater body (i.e., may extend axially from one end face of the resistive heater body 100 to a second end face of the resistive heater body 100).

[0072] In certain embodiments, each current directing feature of a resistive heater body (e.g., resistive heater body 100) can be configured to adjust the path of current flowing through the resistive heater body away from the shortest distance path through the resistive heater body. In other words, each current directing feature can be configured to redirect the path of current flowing through the resistive heater body toward a region of the resistive heater body away from the end of the corresponding slot (e.g., end 107 of slot 106).

[0073] In embodiments, each current directing feature of the resistive heater body may include an arrangement of modified aperture channels (e.g., aperture channels 102). Figure 2A and 2B , shows certain improved cell channels 102 according to various embodiments of the present disclosure. As shown, an array of intersecting cell walls 104, 104' forms a plurality of cell channels 102A, 102B, 102C, 102D. Cell channel 102A is shown as having a single rounded corner 202. Cell channel 102B is shown as having two rounded corners 204. Cell channel 102C is shown as having a single chamfered corner 206. Cell channel 102D is shown as having a single beveled edge 208. Cell channel 102E is shown as having two chamfered corners 210. Although certain fillets, chamfers, bevels, and / or otherwise partially filled cell channels are mentioned, these examples are illustrative only, and it should be understood that other regular and / or irregular geometries are disclosed.

[0074] In certain embodiments, each current directing feature of the resistive heater body can include a combination of an arrangement of thickened bore walls (e.g., walls 104, 104') and an arrangement of a modified bore channel (e.g., bore channel 102). As described herein, the arrangement of thickened bore walls and / or the arrangement of modified bore channels can extend the entire length of the resistive heater body (i.e., can extend axially from one end face of the resistive heater body 100 to a second end face of the resistive heater body 100).

[0075] In the embodiment, reference Figure 3 , shows a portion of a resistive heater body 100 having a first current directing feature 300 according to aspects of the present disclosure. As shown, the current directing feature 300 is disposed near the end 107 of a corresponding slot 106 of the resistive heater body 100. The current directing feature 300 includes a first linear portion 302 extending in a first direction D1 perpendicular to the primary direction of the slot 106 (i.e., direction D3); a second linear portion 304 extending in a second direction D2 perpendicular to the primary direction D3 of the slot 106; and an intermediate / connecting portion 306 having an arrangement of modified aperture channels connecting the first linear portion 302 and the second linear portion 304.

[0076] In an embodiment, the first linear portion 302 and / or the second linear portion 304 of the current directing feature 300 may include a thickened hole wall 104, 104' having a thickness T F Greater than the thickness T of the intersecting hole walls 104, 104' outside the linear portions 302, 304 w In other words, the first linear portion 302 and / or the second linear portion 304 of the current directing feature 300 may include a thickened hole wall 104, 104' having a thickness T F Greater than the average thickness of the intersecting hole walls 104 , 104 ′ of the resistive heater body 100 .

[0077] In an embodiment, the thickness T of the thickened hole wall 104 , 104 ′ of the first linear portion 302 and / or the second linear portion 304 is F The thickness may be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination thereof.

[0078] In an embodiment, the first linear portion 302 and / or the second linear portion 304 of the current directing feature 300 may coincide with the end 107 of the corresponding slot 106. For example, Figure 3 As shown, the first linear portion 302 and the second linear portion 304 extend along the bore wall 104 , which also partially forms the end 107 of the slot 106 .

[0079] In an embodiment, the first linear portion 302 and / or the second linear portion 304 of the current directing feature 300 may extend in the first direction D1 and the second direction D2, respectively, across the plurality of aperture channels 102. In some embodiments, the first linear portion 302 and / or the second linear portion 304 of the current directing feature 300 extend in the first direction D1 and the second direction D2, respectively, until reaching an adjacent slot 106.

[0080] In an embodiment, the current directing feature 300 further includes a middle portion 306 having an arrangement of modified aperture channels connecting the first linear portion 302 and the second linear portion 304. More specifically, the middle portion 306 of the current directing feature 300 includes an arrangement of six aperture channels 102 in a two by three grid. Figure 3In the example of FIG, the middle portion 306 includes: a first modified orifice channel 102 having an outer chamfer; a second modified orifice channel 102 having an opposite outer chamfer; and a first unmodified orifice channel 102 separating the first and second modified orifice channels 102 in a first direction. The middle portion 306 further includes a third modified orifice channel 102 having two inner chamfers adjacent to the first unmodified orifice channel 102 in a second direction, wherein the top and bottom of the third modified orifice channel 102 are surrounded by the unmodified orifice channel 102.

[0081] refer to Figure 4 , shows a portion of another resistive heater body 100 having a second current directing feature 400 according to aspects of the present disclosure. As shown, the current directing feature 400 is disposed near the end 107 of the corresponding slot 106 of the resistive heater body 100 and includes a combination of an arrangement of thickened cell walls (e.g., walls 104, 104') and an arrangement of a modified cell channel (e.g., cell channel 102).

[0082] Specifically, the second current guiding feature 400 includes: a first linear portion 402, which extends in a first direction D1 perpendicular to the main direction of the slot 106 (i.e., direction D3); a second linear portion 404, which extends in a second direction D2 perpendicular to the main direction D3 of the slot 106; and an intermediate / connecting portion 406, which has an arrangement of modified hole channels connecting the first linear portion 402 and the second linear portion 404.

[0083] In an embodiment, the first linear portion 402 and / or the second linear portion 404 of the current directing feature 400 includes a thickened hole wall 104, 104' having a thickness T F Greater than the thickness T of the intersecting hole walls 104, 104' outside the linear portions 402, 404 w In other words, the first linear portion 402 and / or the second linear portion 404 of the current directing feature 400 may include a thickened hole wall 104, 104' having a thickness T F Greater than the average thickness of the intersecting hole walls 104 , 104 ′ of the resistive heater body 100 .

[0084] In an embodiment, the thickness T of the thickened hole wall 104 , 104 ′ of the first linear portion 402 and / or the second linear portion 404 is F The thickness may be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination thereof.

[0085] In embodiments, the first linear portion 402 and / or the second linear portion 404 of the current directing feature 400 may be spaced one or more aperture channels 102 from the end 107 of the corresponding slot 106 (i.e., in a direction toward the outer periphery 118 of the resistive heater body 100). For example, Figure 4 As shown, the first linear portion 402 and the second linear portion 404 extend along the bore wall 104 , which is separated from the end 107 of the slot 106 in the direction D3 by two bore passages.

[0086] In an embodiment, the first linear portion 402 and / or the second linear portion 404 of the current directing feature 400 may extend in the first direction D1 and the second direction D2 , respectively, across the plurality of aperture channels 102 .

[0087] In an embodiment, the current directing feature 400 further includes a middle portion 406 having an arrangement of modified aperture channels connecting the first linear portion 402 and the second linear portion 404. More specifically, the middle portion 406 of the current directing feature 400 includes an arrangement of three aperture channels 102 in a one by three grid. Figure 4 In the example of FIG, the middle portion 406 includes: a first modified hole channel 102 having an outer chamfer; a second modified hole channel 102 having two chamfers; and a third unmodified hole channel 102 having an opposite outer chamfer. As shown, the linear portions 402, 404 connect to the middle portion 406 at the unchamfered corners of the hole channel 102 arrangement.

[0088] refer to Figure 5 , shows a portion of another resistive heater body 100 having a third current directing feature 500 according to aspects of the present disclosure. As shown, the current directing feature 500 is disposed near the end 107 of the corresponding slot 106 of the resistive heater body 100 and includes a combination of an arrangement of thickened cell walls (e.g., walls 104, 104') and an arrangement of a modified cell channel (e.g., cell channel 102).

[0089] Specifically, the second current guiding feature 500 includes: a first linear portion 502, which extends in a first direction D1 perpendicular to the main direction of the slot 106 (i.e., direction D3); a second linear portion 504, which extends in a second direction D2 perpendicular to the main direction D3 of the slot 106; and an intermediate / connecting portion 506, which has an arrangement of modified hole channels connecting the first linear portion 502 and the second linear portion 504.

[0090] In an embodiment, the first linear portion 502 and / or the second linear portion 504 of the current directing feature 500 includes a thickened hole wall 104, 104' having a thickness T FGreater than the thickness T of the intersecting hole walls 104, 104' outside the linear portions 502, 504 w In other words, the first linear portion 502 and / or the second linear portion 504 of the current directing feature 500 may include a thickened hole wall 104, 104' having a thickness T F Greater than the average thickness of the intersecting hole walls 104 , 104 ′ of the resistive heater body 100 .

[0091] In an embodiment, the thickness T of the thickened hole wall 104 , 104 ′ of the first linear portion 502 and / or the second linear portion 504 is F The thickness may be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination thereof.

[0092] In embodiments, the first linear portion 502 and / or the second linear portion 504 of the current directing feature 500 may space one or more aperture channels 102 apart from the end 107 of the corresponding slot 106 (e.g., in a direction away from the outer periphery 118 of the resistive heater body 100). Figure 5 As shown, the first linear portion 502 and the second linear portion 504 extend along the bore wall 104, which is separated from the end 107 of the slot 106 by a bore passage in a direction opposite to the direction D3.

[0093] In an embodiment, the first linear portion 502 and / or the second linear portion 504 of the current directing feature 500 may extend in the first direction D1 and the second direction D2 , respectively, across the plurality of aperture channels 102 .

[0094] In an embodiment, the current directing feature 500 further includes a middle portion 506 having an arrangement of modified aperture channels connecting the first linear portion 502 and the second linear portion 504. More specifically, the middle portion 506 of the current directing feature 500 includes an arrangement of eight aperture channels 102 in a three by three grid. Figure 5 In the example of FIG. 5 , the middle portion 506 includes thickened cell walls 104′ extending in the direction D3, at least partially adjacent to the end 107 of the groove 106. These thickened cell walls 104′ extend to two chamfered cell channels 102, which are separated by an unmodified cell channel 102. The middle portion 506, centered around the end 107 of the groove 106 and adjacent to the unmodified cell channel 102, includes a modified cell channel 102 having two inner chamfers surrounded by the two unmodified cell channels 102.

[0095] As described herein, one or more current directing features (e.g., current directing features 300, 400, 500) can be configured to adjust the path of current flowing through the resistive heater body 100, thereby reducing the generation of cold zones. In certain embodiments, for example, this means that more current is directed to the outer regions of the resistive heater body 100 and away from the ends of the plurality of slots (e.g., end 107 of slot 106).

[0096] refer to Figure 6 , for example, illustrates the heating performance of a resistive heater body 100 having a comparative V-shaped current directing feature 600 centered at the end 107 of the slot 106, in accordance with aspects of the present disclosure. As shown, the resistive heater body 100 experiences a higher temperature (i.e., at least about 500° C.) around the slot 106, and the comparative current directing feature 600 creates a zone of intermediate temperature (i.e., between about 300° C. and about 500° C.), while zones further from the slot 106 are significantly cooler (i.e., between about 0° C. and about 300° C.). Consequently, fluid passing through the bore channels 102 in certain zones of the resistive heater body 100 will experience a significantly different temperature than fluid passing through the bore channels 102 in other zones of the resistive heater body 100.

[0097] Steering Figure 7 、 8 and 9, the first current guiding characteristic, the second current guiding characteristic and the third current guiding characteristic (respectively as Figure 3 、 4 and 5) relative to the heating performance of the comparative current guidance characteristics (as shown in Figure 6 As shown in the figure, the temperature difference between the comparative example and the inventive example is plotted, and thus, the area experiencing a lower temperature in the inventive example has a positive temperature change, while the area experiencing a higher temperature in the inventive example has a negative temperature change. Specifically, the temperature difference of the non-rounded portion of the resistance heater is observed. Figure 7 、 8 As can be seen in FIG. 9 , the first current directing feature, the second current directing feature, and the third current directing feature improve heating performance (ie, higher temperatures) in areas further away from the slot 106 .

[0098] refer to Figures 10A to 16B Also provided herein are resistive heater bodies comprising a combination of one or more elongated slots and one or more current directing features. In embodiments, the one or more current directing features may be one or more of the current directing features 300, 400, 500 described above, but may also include a continuous length of modified pore walls corresponding to a series of adjacent, partially filled pore channels, such as Figures 10A to 16BIn embodiments, one or more of the extension slots may have corresponding ends that are within a predefined distance from the outer periphery of the resistive heater body. In certain embodiments, a portion of the outer periphery of the resistive heater body may be covered (e.g., by a retaining ring, etc.), and one or more of the extension slots may have corresponding ends that are within a predefined distance from the covered portion of the outer periphery.

[0099] For example, reference Figure 10A , shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1002 of the outer periphery 118 of the resistive heater body 100, in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1002 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1004 of the resistive heater body 100.

[0100] exist Figure 10A In the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1006 near the end 107 of the slot 106, wherein the current directing feature 1006 includes a continuous length of modified pore walls 104, 104' corresponding to a series of adjacent, partially filled pore channels 102. In embodiments, a portion of the current directing feature 1006 may be covered by and / or follow the contour of the retaining ring 140. Additionally, as shown in FIG. Figure 10A As shown, the slot 106 includes an end 107 that is at most one bore channel 102 away from the portion 1002 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1002.

[0101] refer to Figure 10B , showing Figure 10A 100. As shown, the current directing features 1006 and the extended slots 106 successfully increase the temperature of the resistive heater body 100 at locations closer to the outer periphery 118 of the resistive heater body 100. However, the current directing features 1006 and the extended slots 106 also increase the temperature of the covered portion 1002 of the resistive heater body 100.

[0102] refer to Figure 11A, shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1102 of the outer periphery 118 of the resistive heater body 100 in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1102 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1104 of the resistive heater body 100.

[0103] In an embodiment, the resistive heater body 100 includes a current directing feature 1106 near the end 107 of the slot 106, wherein the current directing feature 1106 includes a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially filled cell channels 102. Figure 11A In the example of FIG. 1 , a portion of the current directing feature 1106 follows the contour of the retaining ring 140 but is not covered by the retaining ring 140 .

[0104] In addition, if Figure 11A As shown, the slot 106 includes a terminal end 107 that is at most three bore channels 102 away from the portion 1102 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1102.

[0105] refer to Figure 11B , showing Figure 11A 14. The heating performance of the resistive heater body 100 is shown. As shown, the current directing features 1106 and the extended slots 106 successfully reduce the temperature of the covered portion 1002 of the resistive heater body 100, but leave a larger cold spot in the uncovered portion 1004 of the resistive heater body 100. Furthermore, it can be seen that the current directing features 1106 successfully keep the temperature of the area of ​​the heater body 100 adjacent to the retaining ring 140 at a minimum level. That is, in some embodiments, the current directing features 1106 can increase heating at some portions of the heater body 100 while not increasing the temperature of other portions (e.g., the portion covered by the retaining ring 140).

[0106] refer to Figure 12A, shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1202 of the outer periphery 118 of the resistive heater body 100 in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1202 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1204 of the resistive heater body 100.

[0107] exist Figure 12A In the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1206 near the end 107 of the slot 106, wherein the current directing feature 1206 includes a continuous length of modified pore walls 104, 104' corresponding to a series of adjacent, partially filled pore channels 102. The resistive heater body 100 further includes a region 1208 of blocked pore channels, wherein the pore channels are filled to prevent any fluid flow. In embodiments, a portion of the current directing feature 1206 may be covered by and / or follow the contours of the retaining ring 140.

[0108] In addition, if Figure 12A As shown, the slot 106 includes an end 107 that is at most three bore channels 102 away from the portion 1002 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1202.

[0109] refer to Figure 12B , showing Figure 12A 100 . As shown, the current directing features 1206 and the extended slots 106 successfully increase the temperature of locations within the resistive heater body 100 closer to the outer periphery 118. While the blocked area 1208 of the resistive heater body 100 remains cooler, no air flows through the blocked area 1208, and the current directing features 1206 successfully increase the temperature of locations near the blocked area 1208 where the aperture channels 102 are unblocked (i.e., air flow is permitted). Furthermore, it can be seen that the current directing features 1206 successfully keep the temperature of the area of ​​the heater body 100 adjacent to the retaining ring 140 at a minimum level. That is, in some embodiments, the current directing features 1206 can increase heating at some portions of the heater body 100 while not increasing the temperature of other portions (e.g., portions covered by the retaining ring 140).

[0110] refer to Figure 13A, shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1302 of the outer periphery 118 of the resistive heater body 100 in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1302 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1304 of the resistive heater body 100.

[0111] exist Figure 13A In the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1306 near the end 107 of the slot 106, wherein the current directing feature 1306 includes a continuous length of modified aperture walls 104, 104' corresponding to a series of adjacent, partially filled aperture channels 102. In embodiments, a portion of the current directing feature 1306 may be covered by and / or follow the contour of the retaining ring 140. Specifically, unlike the current directing features 1006, 1106, 1206, where a portion extends away from the contour of the retaining ring 140, the entire length of the current directing feature 1306 follows the contour of the retaining ring 140.

[0112] In addition, if Figure 13A As shown, the slot 106 includes an end 107 that is at most two bore channels 102 away from the portion 1302 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1302.

[0113] refer to Figure 13B , showing Figure 13A 100. As shown, the current directing features 1306 and the extended slots 106 successfully increase the temperature of the resistive heater body 100 at locations closer to the outer periphery 118 of the resistive heater body 100. However, the current directing features 1306 and the extended slots 106 also increase the temperature of the covered portion 1302 of the resistive heater body 100.

[0114] refer to Figure 14A, shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1402 of the outer periphery 118 of the resistive heater body 100, in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1402 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1404 of the resistive heater body 100.

[0115] exist Figure 14A In the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1406 near the end 107 of the slot 106, wherein the current directing feature 1406 includes a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially filled cell channels 102. As shown, the current directing feature 1406 further includes a series of adjacent cell channels 102 that are completely filled.

[0116] In embodiments, a portion of the current directing feature 1406 may be covered by the retaining ring 140 and / or follow the contour of the retaining ring 140. Specifically, unlike the current directing features 1006, 1106, 1206, where a portion of the current directing features 1006, 1106, 1206 extends away from the contour of the retaining ring 140, the entire length of the current directing feature 1406 follows the contour of the retaining ring 140.

[0117] In addition, if Figure 14A As shown, the slot 106 includes an end 107 that is at most two bore channels 102 away from the portion 1402 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1402.

[0118] refer to Figure 14B , showing Figure 14A 1. Heating performance of the resistive heater body 100 shown. As shown, the current directing features 1406 and the extended slots 106 successfully increase the temperature of the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0119] refer to Figure 15A, shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1502 of the outer periphery 118 of the resistive heater body 100 in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1502 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1504 of the resistive heater body 100.

[0120] exist Figure 15A In the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1506 near the end 107 of the slot 106, wherein the current directing feature 1506 includes a continuous length of modified aperture walls 104, 104' corresponding to a series of adjacent, partially filled aperture channels 102. Specifically, the current directing feature 1506 includes three adjacent aperture channels 102, each of which has one or more rounded aperture walls 104, 104'.

[0121] In addition, if Figure 15A As shown, the slot 106 includes an end 107 that is at most three bore channels 102 away from the portion 1502 of the resistive heater body 100 that is covered by the retaining ring 140. In other words, in embodiments, the resistive heater body 100 can include a slot 106 that extends into the resistive heater body 100 within less than three bore channels, including within less than two bore channels, and / or within less than one bore channel from the covered portion 1502.

[0122] refer to Figure 15B , showing Figure 15A 1. Heating performance of the resistive heater body 100 shown. As shown, the current directing features 1506 and the elongated slots 106 successfully increase the temperature of the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0123] refer to Figure 16A , shows a portion of a resistive heater body 100 and a retaining ring 140 covering a portion 1602 of the outer periphery 118 of the resistive heater body 100, in accordance with aspects of the present disclosure. In an embodiment, the covered portion 1602 of the resistive heater body 100 does not receive or allow fluid to flow through the bore channel 102, but rather directs fluid through an uncovered portion 1604 of the resistive heater body 100.

[0124] exist Figure 16AIn the example of FIG. 1 , the resistive heater body 100 includes a current directing feature 1606 near the end 107 of the slot 106, wherein the current directing feature 1606 includes a continuous length of modified aperture walls 104, 104' corresponding to a series of adjacent, partially filled aperture channels 102. Specifically, the current directing feature 1606 includes three adjacent aperture channels 102, each of which has one or more rounded aperture walls 104, 104'.

[0125] In addition, if Figure 16A As shown, the slots 106 do not follow a straight path into the resistive heater body 100. In a particular embodiment, each slot 106 extends into the resistive heater body 100 for at least a first length in at least a first direction and at least a second length in at least a second direction. As shown, the slots 106 extend into the resistive heater body 100 for a first length in the first direction D3, a second length in the second direction D2, a third length in the first direction D3, and a fourth length in the second direction D2. Although an irregular slot 106 arrangement is shown, it should be understood that the slots 106 can extend into the resistive heater body 100 in several different directions (including diagonally) and for different lengths.

[0126] In embodiments, the slot 106 may extend into the resistive heater body 100 to within less than three aperture channels from the covered portion 1602, including within less than two aperture channels from the covered portion 1602, and / or within less than one aperture channel from the covered portion 1602.

[0127] refer to Figure 16B , showing Figure 16A Heating performance of the resistive heater body 100 is shown. As shown, the current directing features 1606 and the irregular elongated slots 106 successfully increase the temperature of the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0128] Also provided herein is a fluid treatment system comprising the resistive heater body 100 described herein. Specifically, the fluid treatment system can be adapted to minimize the ignition time of an associated fluid treatment component (e.g., a substrate containing a catalyst), thereby reducing undesirable emissions. For example, referring to Figure 17 , shows a cross-sectional side view of a fluid treatment system 1700 including a catalyst-containing substrate 1725 and a resistive heater body 100 according to aspects of the present disclosure.

[0129] In an embodiment, the catalytic substrate 1725 may be a flow-through honeycomb substrate (e.g., having a plurality of channels formed by intersecting cell walls) containing a catalyst material that can be used to capture undesirable emissions from a fluid stream via a chemical reaction. In some embodiments, the catalyst material is also included in and / or on the walls of the cell channels, such as by washcoating. The catalyst material may include one or more metallic materials for reducing the concentration of exhaust pollutants in the exhaust stream, including but not limited to nitrogen oxides (NO x ), carbon monoxide (CO), and unburned hydrocarbons. The catalyst material may be a selective catalyst reduction (SCR) catalyst. In some embodiments, the catalyst material may be a metal component selected from the group consisting of, for example, platinum, palladium, rhodium, ruthenium, iridium, and combinations thereof. In an embodiment, the catalyst metal material may be gold, silver, copper, or iron. Other oxide catalyst materials, such as oxides of aluminum, zeolites, ceria, lithium, magnesium, calcium, manganese, cobalt, nickel, copper, zinc, and silver, may also be included as part of the catalyst coating. In some embodiments, the catalyst oxide material of the coating may be a SOx adsorbent component, such as Mg or MnO2.

[0130] In embodiments, the resistive heater body 100 can be positioned adjacent to the catalyst substrate 1725 such that the resistive heater body 100 is upstream of the catalyst substrate 1725. Thus, a fluid stream 1723 passing through the fluid handling system 1700 can flow through the cell channels 102 of the resistive heater body 100 and then to the cell channels of the catalyst substrate 1725. In other words, the resistive heater body 100 can be positioned and configured to receive the fluid stream 1723 at a first end face (e.g., into the plurality of cell channels 102) and to deliver the fluid stream 1723 from a second end face to the catalyst substrate 1725.

[0131] In an embodiment, an electrical potential may be applied to the resistive heater body 100 by a control system 1720 that includes a voltage driver 1722 connected to the resistive heater body 100 via electrodes. That is, the control system 1720 is operably connected to the resistive heater body 100 and configured to drive electrical power to the heater body 100 at appropriate times (e.g., at various times during or before operation of an engine coupled to the fluid treatment system 1700). In an embodiment, the control system 1720 is configured to control the timing, duration, and / or magnitude of the electrical potential (e.g., voltage) applied to the resistive heater body 100.

[0132] In certain embodiments, control system 1720 further includes an engine control unit (ECU) 1724. In embodiments, voltage driver 1722 of control system 1720 may control the electrical potential applied to resistive heater body 100 based on a desired thermal profile provided by ECU 1724. The thermal profile may be adapted to reduce cold start emissions, for example, by applying an electrical potential to resistive heater body 100 such that fluid stream 1723 reaches a minimum temperature within a predetermined time period. In embodiments, the minimum temperature achieved may be between approximately 250°C and approximately 650°C, and the predetermined time period may be between approximately 1.0 seconds and approximately 10 seconds. In other embodiments, the minimum temperature achieved by resistive heater body 100 may be determined based on the flow rate of exhaust gas 1723, the temperature of air stream 1723 at the body inlet, the heat transfer coefficient between resistive heater body 100 and air stream 1723, and an applied power based on a target or desired outcome. For example, control system 1720 may receive one or more inputs from temperature sensors 1626 and / or gas sensors 1728 located at various points within treatment system 1700.

[0133] refer to Figures 18A to 18D , illustrates the effects of using a resistive heater body 100 having one or more current directing features described herein, in accordance with aspects of the present disclosure. More specifically, Figure 18A shows the temperature distribution of a substrate (e.g., substrate 1625) positioned downstream of the comparative resistive heater body, while Figures 18B to 18D The temperature distribution of a substrate (e.g., substrate 1725) positioned downstream of a resistive heater body having current directing features 1306, 1406, and 1506, respectively, is shown. As shown, darker shading indicates higher temperatures, while white areas indicate areas of the substrate where the temperature may not be sufficient to convert all of the exhaust passing therethrough. As shown, the current directing features and slot arrangement described in this disclosure reduce the size of the cold zone and improve heating of the downstream catalytic substrate. Additionally, the current directing features and slot arrangement described herein eliminate the formation of hot spots on the heater body 100, which can reduce overall heating uniformity.

[0134] It should be understood that all combinations of the aforementioned concepts and any concepts discussed below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. Specifically, all combinations of the claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be understood that terms explicitly employed herein that may also appear in any disclosure incorporated by reference should be given a meaning most consistent with the specific concepts disclosed herein.

[0135] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0136] Unless explicitly indicated to the contrary, the indefinite articles "a" and "an" as used herein in the specification and claims should be understood to mean "at least one."

[0137] As used herein in the specification and claims, the phrase "and / or" should be understood to mean "either or both" of the elements so conjoined, i.e., the elements are present in conjunction in some cases and separately in other cases. Multiple elements listed with "and / or" should be interpreted in the same manner, i.e., "one or more" of the elements so conjoined. Other elements may optionally be present in addition to the elements specifically identified by the "and / or" clause, whether related or unrelated to those elements specifically identified.

[0138] As used herein in the specification and claims, "or" should be understood to have the same meaning as "and / or" defined above. For example, when separating the items in a list, "or" or "and / or" should be interpreted as inclusive, that is, including many elements or at least one element in a list of elements, but also including more than one element, and optionally other unlisted items. Only terms that clearly indicate the opposite, such as "only one of..." or "exactly one of..." or "consisting of..." when used in the claims will refer to including exactly one element in a plurality of elements or a list of elements. In general, when preceded by exclusive terms such as "any one of," "one of...", "only one of..." or "exactly one of...", the term "or" used herein should only be interpreted as indicating exclusive alternatives (that is, "one or the other but not both").

[0139] As used herein in the specification and claims, the phrase "at least one" in reference to a list of one or more elements should be understood to mean at least one element selected from any one or more elements in the list of elements, but does not necessarily include at least one of each element specifically listed in the list of elements and does not exclude any combination of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to those elements specifically identified.

[0140] As used herein, although the terms first, second, third, etc. may be used herein to describe various elements or components, these elements or components should not be limited by these terms. These terms are only used to distinguish one element or component from another element or component. Therefore, without departing from the teachings of the present invention, the first element or component discussed below may be referred to as the second element or component.

[0141] All ranges disclosed herein are inclusive of the recited endpoints and are independently combinable (e.g., the range of "2 grams to 10 grams" includes the endpoints 2 grams and 10 grams and all intermediate values). The range endpoints and any values ​​disclosed herein are not limited to the precise ranges or values; they are sufficiently imprecise to include values ​​approximating these ranges and / or values.

[0142] As used herein, approximate language may be applied to modify any quantitative representation that may change but does not result in a change in the basic function to which it is associated. Thus, in some cases, a value modified by one or more terms such as "about" and "substantially" may not be limited to the exact value specified. In at least some instances, approximate language may correspond to the precision of the instrument used to measure the value. The modifier "about" should also be considered to disclose a range defined by the absolute values ​​of the two endpoints. For example, the expression "about 2 to about 4" also discloses a range of "2 to 4." The term "about" may refer to plus or minus 10% of the indicated number. For example, "about 10%" may indicate a range of 9% to 11%, and "about 1" may mean 0.9 to 1.1. Other meanings of "about" may be apparent from the context, such as rounding, so that, for example, "about 1" may also mean 0.5 to 1.4.

[0143] For the recitation of numerical ranges herein, each intervening number therebetween with equal precision is expressly contemplated. For example, for the range 6 to 9, in addition to 6 and 9, the numbers 7 and 8 are also contemplated; and for the range 6.0 to 7.0, the numbers 6.0, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are expressly contemplated.

[0144] Unless otherwise specified, when an element or component is referred to as being “connected to,” “coupled to,” or “adjacent to” another element or component, it should be understood that the element or component can be directly connected or coupled to the other element or component, or that intervening elements or components may be present. In other words, these and similar terms encompass situations where one or more intermediate elements or components may be used to connect two elements or components. However, when an element or component is referred to as being “directly connected” to another element or component, this only covers situations where the two elements or components are connected to each other without any intermediate or intervening elements or components.

[0145] In the claims and the foregoing description, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "containing," "consisting of," etc. should be understood as open-ended, i.e., meaning including but not limited to. Only the transitional phrases "consisting of" and "consisting essentially of" should be closed or semi-closed transitional phrases, respectively.

[0146] It should also be understood that in any method claimed herein that includes more than one step or action, the order of the method steps or actions is not necessarily limited to the order in which the method steps or actions are recited unless explicitly indicated to the contrary.

[0147] Although several embodiments of the present invention have been described and illustrated herein, a person of ordinary skill in the art will readily conceive of various other devices and / or structures for performing the functions and / or obtaining the results and / or one or more advantages described herein, and each of such variations and / or modifications is considered to be within the scope of the embodiments of the present invention described herein. More generally, a person of ordinary skill in the art will readily understand that all parameters, dimensions, materials, and configurations described herein are intended to be exemplary, and that actual parameters, dimensions, materials, and / or configurations will depend on one or more specific applications in which the teachings of the present invention are used. A person of ordinary skill in the art will recognize or be able to determine, using only routine experimentation, many equivalents to the specific embodiments of the present invention described herein. Therefore, it should be understood that the foregoing embodiments are presented by way of example only, and within the scope of the appended claims and their equivalents, embodiments of the present invention may be practiced in a manner other than that specifically described and claimed. The embodiments of the present invention disclosed herein relate to each individual feature, system, article, material, kit, and / or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and / or methods is included within the scope of the invention disclosed herein, provided that such features, systems, articles, materials, kits, and / or methods are not mutually inconsistent.

Claims

1. A resistance heater body comprising: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending from an outer periphery of the resistive heater body into the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form the plurality of bore channels in a serpentine pattern from a first side of the resistive heater body to a second side of the resistive heater body; as well as one or more current directing features, each current directing feature being proximate a terminal end of at least one of the plurality of slots, wherein each current directing feature comprises: (i) a first linear portion extending in a first direction perpendicular to the slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) an intermediate portion having one or more modified pore channels connecting the first linear portion and the second linear portion.

2. The resistive heater body of claim 1 , wherein the plurality of bore channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

3. The resistive heater body of claim 1 , wherein the slot extends axially from a first end surface of the resistive heater body to a second end surface of the resistive heater body.

4. The resistive heater body of claim 1 , wherein the first and second linear portions of the one or more current directing features comprise thickened hole walls having a thickness greater than a thickness of the intersecting hole walls.

5. The resistive heater body of claim 1 , wherein the intermediate portion of the one or more current directing features comprises one or more rounded corners and / or chamfered hole walls.

6. The resistive heater body of claim 4 , wherein the first linear portion and the second linear portion of the one or more current directing features comprise thickened hole walls extending in an axial direction from a first end face of the resistive heater body through the resistive heater body to a second end face of the resistive heater body.

7. The resistive heater body of claim 5 , wherein the one or more modified hole walls of the intermediate portion of the one or more current directing features extend in an axial direction from a first end face of the resistive heater body through the resistive heater body to a second end face of the resistive heater body.

8. The resistive heater body of claim 1 , wherein each of the plurality of slots has a width equal to one bore channel.

9. The resistive heater body of claim 8, wherein a center of the intermediate portion of each of the one or more current directing features is one bore channel away from the end of at least one of the plurality of slots.

10. The resistive heater body of claim 1, wherein the end of each of the plurality of slots is spaced at least five bore channels from an outer peripheral region of the resistive heater body.

11. The resistive heater body of claim 1 , wherein each end of one or more of the plurality of slots is separated from an outer peripheral region of the resistive heater body by at most two bore channels.

12. The resistive heater body of claim 1 , wherein one or more of the plurality of slots extend from the outer periphery of the resistive heater body into the resistive heater body for a first length in a first direction and for at least a second length in a second direction.

13. A resistance heater body comprising: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending from an outer periphery of the resistive heater body into the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form the plurality of bore channels in a serpentine pattern from a first side of the resistive heater body to a second side of the resistive heater body; one or more current directing features, each current directing feature proximate an end of at least one of the plurality of slots, wherein each current directing feature comprises a continuous length of modified pore walls corresponding to the array of partially filled pore channels; One or more of the plurality of slots have a corresponding end that is spaced at most two bore channels from an outer peripheral region of the resistive heater body.

14. The resistive heater body of claim 13, wherein the plurality of bore channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

15. The resistive heater body of claim 13, wherein the slot extends axially from a first end face of the resistive heater body to a second end face of the resistive heater body.

16. The resistive heater body of claim 13, wherein at least a portion of one or more of the current directing features follows a contour of the outer peripheral region.

17. The resistive heater body of claim 13, wherein the one or more current directing features further comprise one or more completely filled bore channels along the continuous length of the current directing features.

18. The resistive heater body of claim 13, further comprising one or more regions of completely filled aperture channels, each region being adjacent to the outer perimeter region of the resistive heater body and each region being separated from one or more current directing features by at least one aperture channel.

19. The resistive heater body of claim 13, wherein one or more of the plurality of slots extend from the outer periphery of the resistive heater body into the resistive heater body for a first length in a first direction and for at least a second length in a second direction.

20. A fluid processing system, comprising: a catalyst-containing substrate in fluid communication with a resistive heater body, the resistive heater body positioned upstream of the catalyst-containing substrate; The resistance heater body comprises: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending into the resistive heater body from an outer periphery of the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots form the plurality of bore channels in a serpentine pattern from a first side of the resistive heater body to a second side of the resistive heater body; and One or more current directing features, each current directing feature being located near an end of at least one of the plurality of slots, wherein each current directing feature comprises: (i) a first linear portion extending in a first direction perpendicular to the slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) an intermediate portion having one or more modified pore channels connecting the first linear portion and the second linear portion.

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