Aftertreatment system including a heater assembly

Abstract

A heater assembly includes an inlet body having an inlet body wall having an inlet body wall end portion. The heater assembly includes a heater body having a heater body wall. The heater body wall includes a heater body wall central portion. The heater body wall has a first diameter at the heater body wall central portion. The heater body wall includes a heater body wall outlet flange having a first outlet flange portion extending axially and radially outward from the heater body wall central portion at a first angle with respect to an extending direction of the heater body wall central portion, and a second outlet flange portion extending axially outward from the first outlet flange portion, substantially parallel to the heater body wall central portion, and contiguous with the first outlet flange portion. The heater body wall has a second diameter at the second outlet flange portion.

Description

AFTERTREATMENT SYSTEM INCLUDING A HEATER ASSEMBLYCROSS-REFERENCE TO RELATED APPLICATIONS|0001] This PCT Application claims the benefit of and priority to U. S. Provisional Application No. 63 / 552,858, filed February 13, 2024, which is incorporated herein by reference in its entirety and for all purposes.TECHNICAL FIELD

[0002] The present disclosure relates generally to an exhaust aftertreatment system for an internal combustion engine. More specifically, the present disclosure relates to a heater assembly for the exhaust aftertreatment system.BACKGROUND

[0003] In an internal combustion engine system, an aftertreatment system is used to capture undesirable material and particulate from exhaust gas produced by a combustion of fuel. In assembling an engine system, an aftertreatment system may be provided in exhaust receiving communication with a cylinder block of the engine. However, the aftertreatment system may be complex, having numerous components and joints for coupling the components together.SUMMARY[00041 In one embodiment, a heater assembly includes an inlet body, a heater body, an outlet body, and a heat shield. The inlet body includes an inlet body wall having an inlet body wall end portion. The heater body includes a heater body wall. The heater body wall includes a heater body wall central portion and a heater body wall outlet flange. The heater body wall has a first heater body diameter at the heater body wall central portion. The heater body wall outlet flange includes a first outlet flange portion and a second outlet flange portion. The first outlet flange portion extends axially and radially outward from the heater body wall central portion at a first angle with respect to an extending direction of the heater body wall central portion. The second outlet flange portion extends axially outward from the first outlet flange portion,substantially parallel to the heater body wall central portion, and contiguous with the first outlet flange portion. The heater body wall has a second heater body diameter at the second outlet flange portion. The second heater body diameter is larger than the first diameter. The outlet body includes an outlet body wall. The outlet body wall includes an upstream engagement wall portion. The upstream engagement wall portion includes a first upstream engagement member wall portion, a second upstream engagement member wall portion, and a third upstream engagement member wall portion. The first upstream engagement member wall portion is disposed proximate the heater body wall outlet flange. The outlet body wall has a first outlet body diameter at the first upstream engagement member wall portion. The second upstream engagement member wall portion extends away from the first upstream engagement member wall portion. The outlet body wall has a second outlet body diameter at the second upstream engagement member wall portion. The second outlet body diameter is larger than the first outlet body diameter. The third upstream engagement member wall portion extends away from the second upstream engagement member wall portion. The outlet body wall has a third outlet body diameter at the third upstream engagement member wall portion. The third outlet body diameter is larger than the second outlet body diameter. The heat shield is disposed around the heater body and disposed around at least a portion of the outlet body.

[0005] In another embodiment, a method of assembling an aftertreatment system includes providing a first inlet body having a first configuration. The first inlet body includes a first inlet body wall including a first inlet body wall inlet portion having a first diameter and a first inlet body wall outlet portion having a second diameter. The method includes providing a second inlet body having a second configuration. The second inlet body includes an inlet body wall including a second inlet body wall inlet portion having a third diameter, different than the first diameter, and an inlet body wall outlet portion having the second diameter. The method also includes providing a plurality of heater bodies. Each of the heater bodies having a first heater body wall configuration. The method also includes manufacturing a first aftertreatment system by coupling the first inlet body to the inlet of a first heater body and manufacturing a second aftertreatment system by coupling the second inlet body to the inlet of a second heater body of the plurality of heater bodies.

[0006] In another embodiment, a heater assembly for an aftertreatment system component includes a heater body and a heater. The heater body has a heater body wall. The heater body wall at least partially defines a heater body volume. The heater is disposed in the heater body volume. The heater assembly also includes one or more electrode wires extending through the heater body wall. The heater assembly also includes a mounting bracket body coupled to the heater body wall. The mounting bracket body includes a mounting bracket wall. The mounting bracket wall includes a first mounting bracket wall portion, a second mounting bracket wall portion, and a third mounting bracket wall portion. The first mounting bracket wall portion defines a first mounting bracket opening sized to receive a first fastener. The second mounting bracket wall portion extends outward from the first mounting bracket wall portion at a first angle with respect to an extending direction of the first mounting bracket wall portion and is contiguous with the first mounting bracket wall portion. The third mounting bracket wall portion extends outward from the second mounting bracket wall portion at a second angle with respect to an extending direction of the second mounting bracket wall portion and is contiguous with the second mounting bracket wall portion. The third mounting bracket wall portion defines a second mounting bracket opening sized to receive a second fastener. The heater assembly also includes a retaining bracket body disposed at the third mounting bracket wall portion. The retaining bracket body has a retaining bracket wall. The retaining bracket wall defines a retaining bracket opening sized to receive the second fastener. At least a portion of the retaining bracket body is spaced away from the mounting bracket body such that a gap is defined therebetween. The one or more electrode wires extend through the gap.

[0007] In another embodiment, an aftertreatment system includes a first heater assembly, a first component, and a second heater assembly. The first heater assembly includes a first inlet body. The first inlet body wall includes a first inlet body wall first end portion and a first inlet body wall second end portion. The first inlet body wall first end portion has a first diameter. The first heater assembly includes a first heater body has a first heater body wall. The first heater assembly includes a first outlet body having a first outlet body wall. The first outlet body wall has a first upstream engagement member and a first downstream engagement member. The first downstream engagement member has a second diameter, equal to the first diameter. The firstcomponent is disposed downstream of the first heater assembly. The first component includes an inlet portion having a third diameter, equal to the first diameter. The first component includes an outlet portion having a fourth diameter, equal to the first diameter. The second heater assembly is disposed downstream of the first heater assembly. The second heater assembly includes a second inlet body having a second inlet body wall having a second inlet body wall first end portion and a second inlet body wall second end portion. The second inlet body wall first end portion has a fifth diameter, equal to the first diameter. The second heater assembly includes a second heater body including a second heater body wall. The second heater assembly includes a second outlet body including a second outlet body wall having a second upstream engagement member and a second downstream engagement member. The second downstream engagement member has a sixth diameter, equal to the first diameter.BRIEF DESCRIPTION OF THE DRAWINGS|0008] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying Figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

[0009] Figure 1 is a block diagram of a portion of an aftertreatment system, according to an example embodiment;

[0010] Figure 2 is a block diagram of a portion of an aftertreatment system, according to another example embodiment;

[0011] Figure 3 is a side view of a heater assembly having an example configuration;

[0012] Figure 4 a cross-sectional view of the heater assembly of Figure 3;

[0013] Figure 5 is a side view of a heater assembly having another example configuration;

[0014] Figure 6 is a perspective view of the heater assembly of Figure 5;

[0015] Figure 7 is a side view of a heater assembly having yet another example configuration;

[0016] Figure 8 is a cross-sectional view of the heater assembly of Figure 7;

[0017] Figure 9 is a side view of a heater assembly having yet another example configuration;

[0018] Figure 10 is a cross-sectional view of a heater assembly having yet another example configuration;

[0019] Figure 11 is a cross-sectional view of a heater assembly having yet another example configuration;|0020] Figure 12 is a side view of a heater assembly having another example configuration;|O021] Figure 13 is a cross-sectional view of the heater assembly of Figure 12;|0022] Figure 14 is a side view of a heater assembly having yet another example configuration;|0023] Figure 15 is a cross-sectional view of the heater assembly of Figure 14;|0024] Figure 16 is a first perspective view of the heater assembly of Figure 14;

[0025] Figure 17 is a second perspective view of the heater assembly of Figure 14;

[0026] Figure 18 is a side view of a heater assembly having still another example configuration;|0027] Figure 19 is a cross-sectional view of the heater assembly of Figure 18;|0028] Figure 20 is a first perspective view of the heater assembly of Figure 18;|0029] Figure 21 is a second perspective view of the heater assembly of Figure 18;|0030] Figure 22 is a side view of a heater assembly having yet another example configuration;|O031] Figure 23 is a cross-sectional view of the heater assembly of Figure 22;

[0032] Figure 24 is a cross-sectional view of a heater assembly having still another configuration; and

[0033] Figure 25 is a flow diagram of a method of assembling an aftertreatment system, according to example embodiment.|0034] It will be recognized that the Figures are the schematic representations for purposes of illustration. The Figures are provided for the purpose of illustrating one or more implementations with the explicit understanding that the Figures will not be used to limit the scope of the meaning of the claims.DETAILED DESCRIPTION[0035| Following below are more detailed descriptions of various concepts related to, and implementations of, methods, apparatuses, and for providing a heater assembly for an aftertreatment system. The various concepts introduced above and discussed in greater detail below may be implemented in any of a number of ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.I. Overview[00361 In order to reduce emissions, it may be desirable to treat exhaust gas using an aftertreatment system component, such as a catalyst member. Some catalyst members may operate more efficiently (e.g., remove or reduce more harmful exhaust gas constituents) when operating above a target temperature. Thus, a heater assembly including a heater (e.g., an electric heater) may be positioned within the aftertreatment system to heat (directly or indirectly) the catalyst member. For example, a heater in the aftertreatment system may be couple the heater assembly upstream of the catalyst member to heat the exhaust gas (e.g., so as to enable thermal transfer from the exhaust gas to the catalyst member). In this way, the heater may heat the catalyst member, the exhaust gas, or both. Advantageously, heating catalyst member, the exhaust gas, or both contributes to the conversion efficiency (e.g., the percentage of exhaust gas constituents converted into a desirable chemical or substance) of the aftertreatment system. However, aftertreatment system components upstream or downstream of the heater assembly, such as conduits, housings for catalyst members, housings for filters, orother aftertreatment system components, may vary in size based on the application of the aftertreatment system. One approach for providing heater assemblies in the aftertreatment system may include designing and assembling purpose-built heater assemblies for each aftertreatment system application. However, the use of a specific purpose-built heater assembly increases the overall cost of the aftertreatment system.[0O37| Aftertreatment systems architectures are often specifically designed for each application (e.g., diesel engines, gasoline engines, natural gas engines, propane engines, hydrogen combustion engines, etc.). In some applications, the physical space available for use by an aftertreatment system is limited due to the locations of surrounding components, wiring or piping requirements, and / or other similar constraints. It is often difficult to modify an aftertreatment system because such modifications typically increase the space claim of the aftertreatment system. Such modifications may be desired to utilize various components, such as different types of heaters, in the aftertreatment system.|0038] Implementations described herein are related to a heater assembly for an aftertreatment system the heater assembly includes an inlet body, a heater body, and an outlet body. The heater body houses a heater. The inlet body enables coupling the heater body to an upstream component, such as a conduit or a component housing. The inlet assembly may advantageously be swapped for a different inlet body having a different configuration to accommodate a different upstream component. The outlet body facilitates coupling the heater body to a downstream component, such as a component housing or other component assembly (e.g., a housing for a catalyst member, a catalyst member assembly, or another heater assembly). In this way, internal combustion engines utilizing the aftertreatment system described herein are more desirable than other aftertreatment systems with heater assemblies that cannot be readily adapted (e.g., by changing the inlet body to one of a different configuration) to improve the ease of assembling the aftertreatment system.II. Overview of Example Aftertreatment Systems[0039| Figures 1 and 2 depict various architectures of an internal combustion engine system100 (e.g., a vehicle system, a genset system, power system, etc.) that includes an internalcombustion engine 101 and an aftertreatment system 103 (e.g., treatment system, etc.). The internal combustion engine 101 includes an internal combustion engine (ICE) 102 (e.g., diesel internal combustion engine, gasoline internal combustion engine, hydrogen internal combustion engine, hybrid internal combustion engine, propane internal combustion engine, dual-fuel internal combustion engine, etc.). In some embodiments, the internal combustion engine 101 includes a turbocharger (not shown). The aftertreatment system 103 is configured to treat exhaust produced by the internal combustion engine 102. As is explained in more detail herein, the treatment may facilitate reduction of emission of undesirable components (e.g., nitrogen oxides (NOx), sulfur oxide (SOx), etc.) in the exhaust.[00401 As shown in Figure 1, the aftertreatment system 103 includes an exhaust conduit system 104 (e.g., line system, pipe system, etc.). The exhaust conduit system 104 is configured to facilitate routing of the exhaust produced by the internal combustion engine 102 throughout the aftertreatment system 103 and to atmosphere (e.g., ambient environment, etc.). At least a portion (e.g., segments of, conduits of, etc.) the exhaust conduit system 104 is centered on a conduit axis 106 (e.g., the conduit axis 106 extends through a center point of a conduit of the exhaust conduit system 104, etc.). As used herein, the term “axis” describes a theoretical line extending through the centroid (e.g., center of mass, geometric center, etc.) of an object. The object is centered on the axis. The object is not necessarily cylindrical (e.g., a non-cylindrical shape may be centered on an axis, etc.). In other embodiments, and as shown in Figure 2, at least a portion (e.g., segments of, conduits of, etc.) the exhaust conduit system 104 is not centered on the conduit axis 106.

[0041] The exhaust conduit system 104 includes an intake chamber 108 (e.g., line, pipe, conduit, etc.). The intake chamber 108 is configured to receive exhaust from the internal combustion engine 102. The intake chamber 108 may receive exhaust from a portion of the internal combustion engine 102 (e.g., header on the internal combustion engine, exhaust manifold on the internal combustion engine, the internal combustion engine, etc.). In some embodiments, the intake chamber 108 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, bonded, pinned, press-fit, etc.) to the internal combustion engine 102. In other embodiments, the intake chamber 108 is integrally formed with the internalcombustion engine 102. As utilized herein, two or more elements are “integrally formed” with each when the two or more elements are formed and joined together as part of a single manufacturing process to create a single-piece or unitary construction that cannot be disassembled without an at least partial destruction of the overall component. The intake chamber 108 may be centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the intake chamber 108, etc.). In some embodiments, the intake chamber 108 may be offset from the conduit axis 106 (e g., the conduit axis 106 extends adjacent to a center point of the intake chamber 108, etc.).

[0042] In some embodiments, the exhaust conduit system 104 also includes an introduction conduit 109 (e.g., decomposition housing, decomposition reactor, decomposition chamber, reactor pipe, decomposition tube, reactor tube, etc.). The introduction conduit 109 is configured to receive exhaust from the intake chamber 108. In various embodiments, the introduction conduit 109 is coupled to the intake chamber 108. For example, the introduction conduit 109 may be fastened (e g., using a band clamp, using bolts, using twist-lock fasteners, threaded, etc.) to the intake chamber 108. In other embodiments, the introduction conduit 109 is integrally formed with the intake chamber 108. As utilized herein, the terms “fastened,” “fastening,” and the like, describe attachment (e.g., joining, etc.) of two structures in such a way that detachment (e.g., separation, etc.) of the two structures remains possible while “fastened” or after the “fastening” is completed, without destroying or damaging either or both of the two structures. The introduction conduit 109 is centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the introduction conduit 109, etc.). In some embodiments, the introduction conduit 109 is formed by the coupling of the individual housings, chambers, assemblies, and / or conduits, as described herein.

[0043] The aftertreatment system 103 includes a heater assembly 120 (e.g., a first heater assembly). The heater assembly 120 is positioned downstream of the internal combustion engine 101. The heater assembly 120 may be positioned downstream of the intake chamber

[0044] The heater assembly 120 includes a heater assembly housing 122. The heater assembly housing 122 is coupled to the intake chamber 108. The heater assembly housing 122 may also be integrally formed with the intake chamber 108. f0045] The heater assembly 120 also includes a heater 124 (e.g., an electric heater, etc.). The heater 124 is positioned within the heater assembly housing 122. The heater 124 may be coupled to the heater assembly housing 122. The heater 124 is operable to heat exhaust flowing through the heater assembly housing 122. For example, as the exhaust flows the through the heater assembly housing 122, the heater assembly housing 122 heats the exhaust. The heated exhaust may then transfer the heat to one or more other components of the aftertreatment system 103. In this way, the heater 124 is capable of heating one or more components of the aftertreatment system 103 that are downstream of the heater assembly 120. The heater assembly 120 is described in greater detail herein with respect to Figures 3-24.|0046] The aftertreatment system 103 includes an oxidation catalyst member 126 (e.g., a first oxidation catalyst member). The oxidation catalyst member 126 is positioned downstream of the internal combustion engine 101. The oxidation catalyst member 126 may be positioned downstream of the heater assembly 120. The oxidation catalyst member 126 includes an oxidation catalyst housing 128. The oxidation catalyst housing 128 is coupled to the heater assembly 120.|<M)47] The oxidation catalyst member 126 also includes an oxidation catalyst substrate 130 (e.g., DOC, etc.). The oxidation catalyst substrate 130 is positioned within the oxidation catalyst housing 128. The oxidation catalyst substrate 130 may be coupled to the oxidation catalyst housing 128. The exhaust including NOx reacts with the oxidation catalyst substrate 130 and cause the conversion (e.g., via oxidation) of nitrogen monoxide (NO) to nitrogen dioxide (NO2) in the exhaust. For example, as the exhaust flows the through the oxidation catalyst substrate 130, the NO reacts with the oxidation catalyst substrate 130 and begins to oxidize. The oxidation catalyst substrate 130 facilitates conversion of the NO in the exhaust into NO2. The oxidation catalyst substrate 130 may also facilitate conversion (e.g., via oxidation) of the carbon monoxide (CO) in the exhaust into carbon dioxide (CO2). Forexample, as the exhaust flows the through the oxidation catalyst substrate 130, the CO reacts with the oxidation catalyst substrate 130 and begins to oxidize into carbon dioxide.|0048] The aftertreatment system 103 also includes a particulate filter assembly 132. The particulate filter assembly 132 includes a particulate filter housing 134. The particulate filter housing 134 is positioned downstream of the oxidation catalyst housing 128. In some embodiments, the particulate filter housing 134 is coupled to the oxidation catalyst housing 128. In some embodiments, the particulate filter housing 134 is integrally formed with the oxidation catalyst housing 128. The particulate filter assembly 132 includes a particulate filter 136 (e.g., particulate filter (PF), filtration member, etc.). The particulate filter 136 is disposed within the particulate filter housing 134 such that the particulate filter 136 is positioned downstream of the oxidation catalyst member 126 (i.e., the oxidation catalyst member 126 is positioned upstream of the particulate filter assembly 132). In some embodiments, the particulate filter housing 134 and the particulate filter 136 are positioned downstream of the intake chamber 108.[0049| The particulate filter 136 is configured to remove particulates (e.g., soot, solidified hydrocarbons, ash, etc.) from the exhaust. For example, the particulate filter 136 may receive exhaust (e.g., from the oxidation catalyst member 126, from the intake chamber 108, etc.) having a first concentration of the particulates and may provide the exhaust downstream having a second concentration of the first particulates, where the second concentration is lower than the first concentration. In this way, the particulate filter 136 may facilitate reduction of a particulate number (PN) of the exhaust. Decreasing the PN of the exhaust may be desirable in a variety of applications. For example, emissions regulations may prescribe a maximum PN for exhaust emitted to atmosphere and the particulate filter 136 may ensure that the PN of the exhaust emitted to atmosphere by the aftertreatment system 103 is below the maximum PN. f0050] The aftertreatment system 103 includes a mixing assembly 138. The a mixing assembly 138 includes a mixer housing 140 The mixer housing 140 is positioned downstream of the particulate filter assembly 132. In some embodiments, the mixer housing 140 is coupled to the particulate filter assembly 132. In some embodiments, the mixer housing 140 is integrallyformed with the particulate filter assembly 132. The mixing assembly 138 includes a mixer 142 (e.g., a swirl mixer, mixing plate, vane mixer, co-swirl mixer, counter-swirl mixer, etc.). The mixer 142 is configured to mix the exhaust flowing through the mixing assembly 138 with a reductant fluid (described below). The mixer 142 is disposed within the mixer housing 140. The mixer 142 is positioned downstream of the particulate filter assembly 132 (i.e., the particulate filter assembly 132 is positioned upstream of the mixing assembly 138). In some embodiments, the mixer housing 140 and the mixer 142 are positioned downstream of the intake chamber 108.

[0051] In some embodiments, the mixing assembly 138 is coupled to a first portion 144 of the exhaust conduit system 104. The first portion 144 may be a conduit, an adapter, or other suitable component configured to route the exhaust gas from the mixing assembly 138 to a downstream component. In some embodiments, the mixing assembly 138 is integrally formed with the first portion 144 of the exhaust conduit system 104.

[0052] The aftertreatment system 103 also includes a fluid delivery system 150. As is explained in more detail herein, the fluid delivery system 150 is configured to facilitate the introduction of one or more fluids (e.g., a liquid, a gas, or a combination thereof), such as a reductant (e.g., Adblue®, a urea-water solution (UWS), an aqueous urea solution, AUS32, etc.) and / or air (e.g., ambient air) into the exhaust. When the reductant is introduced into the exhaust, reduction of emission of undesirable components in the exhaust using the aftertreatment system 103 may be facilitated.[00531 As shown in Figure 1, the fluid delivery system 150 includes a first dosing module 152 (e.g., doser, etc.). The first dosing module 152 is configured to facilitate passage of the reductant fluid through the exhaust conduit system 104 and into the exhaust conduit system 104. In some embodiments, the first dosing module 152 is configured to facilitate passage of the reductant fluid into the CDV 138. In some embodiments, the first dosing module 152 is positioned within a dosing module mount. The dosing module mount is configured to facilitate mounting of the first dosing module 152 to the exhaust conduit system 104. The dosing modulemount may provide insulation (e.g., thermal insulation, vibrational insulation, etc.) between the first dosing module 152 and the exhaust conduit system 104.

[0054] The fluid delivery system 150 also includes a reductant fluid source 154 (e.g., reductant tank, etc.). The reductant fluid source 154 is configured to contain the reductant fluid. The reductant fluid source 154 is configured to provide the reductant fluid to the first dosing module 152. The reductant fluid source 154 may include multiple reductant fluid sources 154 (e.g., multiple tanks connected in series or in parallel, etc.). The reductant fluid source 154 may be, for example, an exhaust fluid tank containing urea or a urea mixture.|0055] The fluid delivery system 150 also includes a reductant fluid pump 156 (e.g., supply unit, etc.). The reductant fluid pump 156 is configured to receive the reductant fluid from the reductant fluid source 154 and to provide the reductant fluid to the first dosing module 152. The reductant fluid pump 156 is used to pressurize the reductant fluid from the reductant fluid source 154 for delivery to the first dosing module 152. In some embodiments, the reductant fluid pump 156 is pressure controlled. In some embodiments, the reductant fluid pump 156 is coupled to a chassis of a vehicle associated with the aftertreatment system 103.

[0056] In some embodiments, the fluid delivery system 150 also includes a reductant fluid filter 158. The reductant fluid filter 158 is configured to receive the reductant fluid from the reductant fluid source 154 and to provide the reductant fluid to the reductant fluid pump 156. The reductant fluid filter 158 filters the reductant fluid prior to the reductant fluid being provided to internal components of the reductant fluid pump 156. For example, the reductant fluid filter 158 may inhibit or prevent the transmission of solids to the internal components of the reductant fluid pump 156. In this way, the reductant fluid filter 158 may facilitate prolonged desirable operation of the reductant fluid pump 156.|(M)57[ The first dosing module 152 includes a first dosing module injector 160 (e.g., insertion device, etc.). The first dosing module injector 160 configured to receive the reductant fluid from the reductant fluid pump 156, and to dose (e g., provide, inject, insert, etc.) the reductant fluid received by the first dosing module 152 into the exhaust within the exhaust conduit system 104.

[0058] In some embodiments, the fluid delivery system 150 also includes an air source 162 (e.g., air intake, etc.) and an air pump 164. The air pump 164 is configured to receive air from the air source 162. The air pump 164 is configured to provide the air to the first dosing module 152. In some applications, the first dosing module 152 is configured to mix the air and the reductant fluid into an air-reductant fluid mixture and to provide the air-reductant fluid mixture to the first dosing module injector 160 (e.g., for dosing into the exhaust within the exhaust conduit system 104, etc.). As used herein, it is understood that a reductant fluid may include or consistent of an air-reductant fluid mixture.

[0059] The first dosing module injector 160 is configured to receive the air from the air pump 164. The first dosing module injector 160 is configured to dose the air into the exhaust within the exhaust conduit system 104. In some of these embodiments, the fluid delivery system 150 also includes an air filter 166. The air filter 166 is configured to receive the air from the air source 162 and to provide the air to the air pump 164. The air filter 166 is configured to filter the air prior to the air being provided to the air pump 164. In other embodiments, the fluid delivery system 150 does not include the air pump 164 and / or the fluid delivery system 150 does not include the air source 162. In such embodiments, the first dosing module 152 is not configured to mix the reductant fluid with the air.|0060] In various embodiments, the first dosing module 152 is configured to receive air and reductant fluid, and to dose the reductant fluid into the exhaust conduit system 104 (e.g., via the injector 160). In various embodiments, the first dosing module 152 is configured to receive reductant fluid (and does not receive air) and dose the reductant fluid into the exhaust conduit system 104 (e.g., via the injector 160).|0061] In some embodiments, the fluid delivery system 150 includes additional dosing modules (e.g., a second dosing module, a third dosing module, etc.) that are substantially similar to or the same as the dosing module 152 but located at a different position in the aftertreatment system 103.

[0062] As shown in Figure 1, the internal combustion engine system 100 also includes a controller 170 (e.g., control circuit, driver, etc.). The first dosing module 152, the reductantfluid pump 156, and the air pump 164, are electrically or communicatively coupled to the controller 170. The controller 170 is configured to cause the first dosing module 152 to dose the reductant fluid into exhaust conduit system 104. The controller 170 may also be configured to cause the reductant fluid pump 156 and / or the air pump 164 to dose the reductant fluid and / or air into the exhaust conduit system 104 in order to adjust an amount of the reductant fluid that is dosed into the exhaust conduit system 104.

[0063] The controller 170 includes a processing circuit 172. The processing circuit 172 includes a processor 174 and a memory 176. The processor 174 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory 176 may include, but is not limited to, electronic, optical, magnetic, or any other storage or transmission device capable of providing a processor, ASIC, FPGA, etc. with program instructions. The memory 176 may include a memory chip, Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), flash memory, or any other suitable memory from which the controller 170 can read instructions. The instructions may include code from any suitable programming language. The memory 176 may include various modules that include instructions that are configured to be implemented by the processor 174.|0064] In various embodiments, the controller 170 is configured as a central controller (e.g., engine control unit (ECU), engine control module (ECM), etc.) that is configured control the internal combustion engine 101.

[0065] In some embodiments, the controller 170 is communicable with a display device (e.g., screen, monitor, touch screen, heads up display (HUD), indicator light, etc.). The display device may be configured to change state in response to receiving information from the controller 170. For example, the display device may be configured to change between a static state and an alarm state based on a communication from the controller 170. By changing state, the display device may provide an indication to a user of a status of the fluid delivery system 150.

[0066] In some embodiments, the aftertreatment system 103 includes a second heater assembly 180. The second heater assembly 180 is positioned downstream of the first heater assembly 120. The heater assembly 120 may be positioned downstream of the intake chamber 108. As shown in Figures 1 and 2, the second heater assembly 180 is positioned downstream of the oxidation catalyst member 126, the particulate filter assembly 132, and the CDV 138. In some embodiments, the second heater assembly 180 is coupled to the first portion 144 of the exhaust conduit system 104. In some embodiments, the second heater assembly 180 is coupled to the first portion 144 of the exhaust conduit system 104. In some embodiments, the second heater assembly 180 is integrally formed with the first portion 144 of the exhaust conduit system 104.[0067| The second heater assembly 180 is substantially identical to or is identical to the heater assembly 120. For example, the second heater assembly 180 includes a heater assembly housing 182. The heater assembly 180 also includes a heater 184 (e.g., an electric heater, etc.). The heater 184 is positioned within the heater assembly housing 182. The heater 124 may be coupled to the heater assembly housing 182. The heater 184 is operable to heat exhaust flowing therethrough. The heater assembly 180 is described in greater detail herein with respect to Figures 3-24.

[0068] In some embodiments, the second heater assembly 180 is coupled to a first portion 144 of the exhaust conduit system 104. The second portion 185 may be a conduit, an adapter, or other suitable component configured to route the exhaust gas from the second heater assembly 180 to a downstream component. In some embodiments, the second heater assembly 180 is coupled to the second portion 185 of the exhaust conduit system 104.

[0069] The aftertreatment system 103 includes a catalyst member 186 (e.g., conversion catalyst member, selective catalytic reduction (SCR) catalyst member, catalytic metals, etc ). The catalyst member 186 is positioned downstream of the intake chamber 108. As shown in Figures 1 and 2, the catalyst member 186 is positioned downstream of the first heater assembly 120, the oxidation catalyst member 126, the particulate filter assembly 132, the CDV 138, and the second heater assembly 180.

[0070] The catalyst member 186 is configured to cause decomposition of components of the exhaust using the reductant fluid (e.g., via catalytic reactions, etc.). The catalyst member 186 includes a catalyst housing 188. The catalyst housing 188 may be coupled to the second portion 185 of the exhaust conduit system 104. In some embodiments, the catalyst housing 188 is coupled to the second portion 185 of the exhaust conduit system 104. In some embodiments, the catalyst housing 188 is integrally formed with the second portion 185 of the exhaust conduit system 104. The catalyst member 186 includes a catalyst substrate 190. The catalyst substrate 190 is coupled to the catalyst housing 188. In some embodiments, the catalyst substrate 190 is integrally formed with the catalyst housing 188.(00711 The catalyst member 186 receives the exhaust from the second portion 185 of the exhaust conduit system 104. The exhaust flows through the catalyst substrate 190 and reacts with the catalyst substrate 190 so as to cause the exhaust to undergo the processes of evaporation, thermolysis, and / or hydrolysis to form non-NOx emissions within the introduction conduit 109 and / or the catalyst member 186. In some embodiments, the exhaust and the reductant fluid within the exhaust react with the catalyst substrate 190. In this way the catalyst member 186 is configured to assist the reduction of NOx emissions by accelerating a NOXreduction process between the reductant (e.g., NH3 and / or H2) and the NOXof the exhaust into diatomic nitrogen, water, and / or carbon dioxide.

[0072] The reduction of NOxis referred to herein as “deNOx.” As used herein the “deNOx performance” of the aftertreatment system 103, or more specifically, the catalyst substrate 190, refers to an amount or percentage of NOx that is reduced by the aftertreatment system 103.

[0073] In some embodiments, the aftertreatment system 103 includes a second catalyst member 192 (e.g., conversion catalyst member, selective catalytic reduction (SCR) catalyst member, catalytic metals, etc.). The second catalyst member 192 is positioned downstream of the intake chamber 108. As shown in Figures 1 and 2, the second catalyst member 192 is positioned downstream of the first heater assembly 120, the oxidation catalyst member 126, the particulate filter assembly 132, the CDV 138, and the second heater assembly 180.

[0074] The second catalyst member 192 is configured to cause decomposition of components of the exhaust using the reductant fluid (e.g., via catalytic reactions, etc.). The second catalyst member 192 is substantially similar to or the same as the catalyst member 186. For example, the second catalyst member 192 includes a second catalyst housing 194 and a second catalyst substrate 196 that are substantially similar to or the same as the catalyst housing 188 and the catalyst substrate 190.

[0075] As shown in Figures 1 and 2, the second catalyst member 192 is positioned in parallel with the first catalyst member 186. In this way, the first catalyst member 186 and the second catalyst member 192 define a split flow path. The second catalyst housing 194 may be coupled to the second portion 185 of the exhaust conduit system 104. In some embodiments, the second catalyst housing 194 is coupled to the second portion 185 of the exhaust conduit system 104. In some embodiments, the second catalyst housing 194 is integrally formed with the second portion 185 of the exhaust conduit system 104.

[0076] The aftertreatment system 103 includes an ammonia slip catalyst substrate 197. The ammonia slip catalyst substrate 197 is positioned downstream of the catalyst member 186. In some embodiments, the ammonia slip catalyst substrate 197 is a coating applied to a portion of the outlet of the catalyst member 186. The ammonia slip catalyst substrate 197 is configured to receive the exhaust from the catalyst member 186 and assist in the reduction of the byproducts (e.g., ammonia, etc.) of the processes of the first dosing module 152 and the catalyst member 186. Specifically, the first dosing module 152 may introduce ammonia into the exhaust, however a portion of the ammonia introduced may not react with the exhaust. As a result, excess ammonia may slip from the catalyst member 186 into the exhaust downstream of the catalyst member 186. The ammonia slip catalyst substrate 197 functions to reduce the ammonia such that the exhaust downstream of the ammonia slip catalyst substrate 197 does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 103 does not include the ammonia slip catalyst substrate 197.

[0077] The aftertreatment system 103 includes a second ammonia slip catalyst substrate 198.The second ammonia slip catalyst substrate 198 is positioned downstream of the secondcatalyst member 192. In some embodiments, the second ammonia slip catalyst substrate 198 is a coating applied to a portion of the outlet of the second catalyst member 192. The second ammonia slip catalyst substrate 198 is configured to receive the exhaust from the second catalyst member 192 and assist in the reduction of the byproducts (e.g., ammonia, etc.) of the processes of the first dosing module 152 and the second catalyst member 192. Specifically, the first dosing module 152 may introduce ammonia into the exhaust, however a portion of the ammonia introduced may not react with the exhaust. As a result, excess ammonia may slip from the second catalyst member 192 into the exhaust downstream of the second catalyst member 192. The second ammonia slip catalyst substrate 198 functions to reduce the ammonia such that the exhaust downstream of the second ammonia slip catalyst substrate 198 does not contain an undesirable amount of ammonia. In some embodiments, the aftertreatment system 103 does not include the second ammonia slip catalyst substrate 198.

[0078] The aftertreatment system 103 also includes an outlet chamber 199. The outlet chamber 199 is positioned downstream of the catalyst member 186 and the second catalyst member 192. The outlet chamber 199 is configured to receive the exhaust from the catalyst member 186 and the second catalyst member 192. In various embodiments, the outlet chamber 199 is coupled to the catalyst member 186 and the second catalyst member 192. For example, the outlet chamber 199 may be fastened to the catalyst member 186 and the second catalyst member 192. In some embodiments, the outlet chamber 199 is coupled to the introduction conduit 109. In some embodiments, the outlet chamber 199 is the introduction conduit 109 (e.g., only the introduction conduit 109 is included in the exhaust conduit system 104 and the introduction conduit 109 functions as both the introduction conduit 109 and the outlet chamber 199). The outlet chamber 199 may be centered on the conduit axis 106 (e.g., the conduit axis 106 extends through a center point of the outlet chamber 199, etc.).[0079| In various embodiments, the exhaust conduit system 104 only includes a single conduit that functions as the intake chamber 108, the introduction conduit 109, and the outlet chamber 199.

[0080] In various embodiments, the aftertreatment system 103 also includes a first sensor 200 (e.g., NOx sensor, NH3 sensor, O2 sensor, particulate sensor, nitrogen sensor, etc.). The first sensor 200 is positioned downstream of the internal combustion engine 101 and upstream of the first heater assembly 120. The first sensor 200 is configured to measure (e.g., sense, detect, etc.) a first parameter (e.g., NOx concentration, NH3 concentration, O2 concentration, particulate concentration, nitrogen concentration, SOx concentration, etc.) of the exhaust downstream of the internal combustion engine 101. The first sensor 200 may be configured to measure the first parameter within the exhaust conduit system 104. In some embodiments, the first parameter measured by the first sensor 200 is an engine out NOx value (i.e., “EONOx”). The first sensor 200 is electrically or communicatively coupled to the controller 170 and is configured to provide a first signal associated with the first parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a first measurement of the first parameter based on the first signal.[00811 In various embodiments, the aftertreatment system 103 also includes a second sensor 202 (e.g., temperature sensor, etc.). The second sensor 202 is positioned downstream of the first heater assembly 120 and upstream of the oxidation catalyst member 126. The second sensor 202 is configured to measure (e.g., sense, detect, etc.) a second parameter (e.g., temperature, etc.) of the exhaust downstream of first heater assembly 120. The second sensor 202 may be configured to measure the second parameter within or downstream of the heater assembly 120. In some embodiments, the second parameter measured by the second sensor 202 is a temperature of the exhaust downstream of the first heater assembly 120. The second sensor 202 is electrically or communicatively coupled to the controller 170 and is configured to provide a second signal associated with the second parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a second measurement of the second parameter based on the second signal.

[0082] In various embodiments, the aftertreatment system 103 also includes a third sensor 204 (e.g., temperature sensor, pressure sensor, etc.). The third sensor 204 is positioned downstream of the oxidation catalyst member 126 and upstream of the particulate filter assembly 132. The third sensor 204 is configured to measure (e.g., sense, detect, etc.) a third parameter (e.g.,temperature, pressure, etc.) of the exhaust downstream of oxidation catalyst member 126. The third sensor 204 may be configured to measure the third parameter within or downstream of the oxidation catalyst member 126. In some embodiments, the third parameter measured by the third sensor 204 is a temperature of the exhaust downstream of the oxidation catalyst member 126. In some embodiments, the third parameter measured by the third sensor 204 is a pressure of the exhaust downstream of the oxidation catalyst member 126. The third sensor 204 is electrically or communicatively coupled to the controller 170 and is configured to provide a third signal associated with the third parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a third measurement of the third parameter based on the third signal.

[0083] In various embodiments, the aftertreatment system 103 also includes a fourth sensor 206 (e.g., temperature sensor, pressure sensor, etc.). The fourth sensor 206 is positioned downstream of the particulate filter assembly 132 and upstream of the CDV 138. The fourth sensor 206 is configured to measure (e.g., sense, detect, etc.) a fourth parameter (e.g., temperature, pressure, etc.) of the exhaust downstream of the particulate filter assembly 132. The fourth sensor 206 may be configured to measure the fourth parameter within or downstream of the particulate filter assembly 132. In some embodiments, the fourth parameter measured by the fourth sensor 206 is a temperature of the exhaust downstream of the particulate filter assembly 132. In some embodiments, the fourth parameter measured by the fourth sensor 206 is a pressure of the exhaust downstream of the particulate filter assembly 132. In some embodiments, the fourth parameter measured by the fourth sensor 206 is a change in pressure of the exhaust downstream across the particulate filter assembly 132 (e.g., relative to the pressure measured by the third sensor 204 upstream of the particulate filter assembly 132. The fourth sensor 206 is electrically or communicatively coupled to the controller 170 and is configured to provide a fourth signal associated with the fourth parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a first measurement based on the fourth signal.

[0084] In various embodiments, the aftertreatment system 103 also includes a fifth sensor 208(e.g., temperature sensor, etc.). The fifth sensor 208 is positioned downstream of the secondheater assembly 180 and upstream of the first catalyst member 186 and / or the second catalyst member 192. The fifth sensor 208 is configured to measure (e.g., sense, detect, etc.) a fifth parameter (e.g., temperature, etc.) of the exhaust downstream of the second heater assembly 180. The fifth sensor 208 may be configured to measure the fifth parameter within or downstream of the second heater assembly 180. In some embodiments, the fifth parameter measured by the fifth sensor 208 is a temperature of the exhaust downstream of the second heater assembly 180. The fifth sensor 208 is electrically or communicatively coupled to the controller 170 and is configured to provide a fifth signal associated with the fifth parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a first measurement based on the fifth signal.

[0085] In various embodiments, the aftertreatment system 103 also includes a sixth sensor 210 (e.g., NOx sensor, NH3 sensor, O2 sensor, particulate sensor, nitrogen sensor, temperature sensor, etc.). The sixth sensor 210 is positioned downstream of the first catalyst member 186 and / or the second catalyst member 192. The sixth sensor 210 is configured to measure (e.g., sense, detect, etc.) a sixth parameter (e.g., NOx concentration, NH3 concentration, O2 concentration, particulate concentration, nitrogen concentration, SOx concentration, temperature, etc.) of the exhaust downstream of the second heater assembly 180. The sixth sensor 210 may be configured to measure the sixth parameter within or downstream of the first catalyst member 186 and / or the second catalyst member 192. In some embodiments, the sixth parameter measured by the sixth sensor 210 is a temperature of the exhaust downstream of the first catalyst member 186 and / or the second catalyst member 192. In some embodiments, the sixth parameter measured by the sixth sensor 210 is a NOx concentration in the exhaust downstream of the first catalyst member 186 and / or the second catalyst member 192, also referred to herein as a system out NOx concentration (i.e., SONOx). The sixth sensor 210 is electrically or communicatively coupled to the controller 170 and is configured to provide a sixth signal associated with the sixth parameter to the controller 170. The controller 170 (e.g., via the processing circuit 172, etc.) is configured to determine a first measurement based on the sixth signal.III. Overview of Example Heater Assemblies

[0086] Now referring to Figures 3-24, various views of a heater assembly 300 are shown in various example configurations. The heater assembly 300 may be used in the aftertreatment system 103. For example, the heater assembly 300 may be utilized in place of the first heater assembly 120 and / or the second heater assembly 180.[00871 The heater assembly 300 is configured to heat exhaust gas produced by an internal combustion engine, such as the internal combustion engine 102. As explained in more detail herein, the heater assembly 300 facilitates simplified assembly compared to assembly of other systems (e.g., by providing different heater inlet body configurations thereby enabling the heater to be coupled to different upstream components, etc.), thereby making the heater assembly 300 more desirable than other systems. More specifically, the heater assembly 300 may be assembled using an inlet body that corresponds to a target application (e.g., model number, manufacturer, engine displacement, etc.) of the heater assembly 300.

[0088] Furthermore, the inlet bodies usable with the heater assembly 300 may enable the use (or re-use) of a standard heater body and a standard outlet body. That is, while the inlet body may be provided in any one of a multitude of configurations, the other components of the heater assembly 300 may remain the same. In this way, the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).10089] In an example embodiment, a business or other suitable entity manufacturing the heater assembly 300 may manufacture many heater assemblies 300. The business may assemble a first heater assembly for a first target application using a first inlet body suitable for use in the first target application. The first heater assembly 300 is assembled using a heater body and an outlet body described herein. The business may also assemble a second heater assembly 300 for a second target application using a second inlet body suitable for use in the second target application. The second inlet body is different than the first inlet body, and the second target application is different than the first target application. The second heater assembly 300 isassembled using a heater body and an outlet body having the same configuration as the heater body and outlet body of the first heater assembly.

[0090] Referring first to Figures 3 and 4, the heater assembly 300 is shown in a first configuration. The heater assembly 300 includes an inlet body 310 (e.g., a first inlet body 310), a heater body 330, and an outlet body 350. The inlet body 310 is coupled to a first end of the heater body 330. The inlet body 310 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or another component of the aftertreatment system 103. The outlet body 350 is coupled to a second end of the heater body 330, opposite the first end. The outlet body 350 facilitates coupling the heater assembly 300 to a downstream component, such as a conduit or another component of the aftertreatment system 103.[00911 The inlet body 310 includes an inlet body wall 312. The inlet body wall 312 includes an inlet body wall first end portion 314 (e g., an inlet portion) and an inlet body wall second end portion 317 (e g., an outlet portion). The inlet body wall first end portion 314 is disposed at a first end of the inlet body wall 312. The inlet body wall second end portion 317 is disposed at a second end of the inlet body wall 312, substantially opposite the first end.

[0092] The inlet body wall first end portion 314 has a first diameter. The inlet body wall first end portion 314 is centered on an inlet axis 316 of the heater assembly 300 (e.g., the inlet axis 316 extends through a center point of the inlet body wall first end portion 314, etc.). The inlet body wall first end portion 314 defines an inlet body first opening 315. The inlet body 310 is configured to receive exhaust from an upstream component via the inlet body first opening 315.

[0093] The inlet body wall second end portion 317 has a second diameter. In some embodiments, the second diameter is different than the first diameter. For example, the second diameter may be larger than the first diameter. The inlet body wall second end portion 317 is centered on an outlet axis 318 of the heater assembly 300 (e.g., the outlet axis 318 extends through a center point of the inlet body wall second end portion 317, etc.). The outlet axis 318 is angled with respect to the inlet axis 316. For example, an angle between the inlet axis 316 and the outlet axis 318 is greater than 0° and less than 180°. As shown in FIG. 3, the angle between the inlet axis 316 and the outlet axis 318 is 90°. In some embodiments, and as shown,the inlet axis 316 intersects the outlet axis 318. In other embodiments, the inlet axis 316 may also feature a dimensional offset from the outlet axis 318. For example, the inlet axis 316 may be spaced away from the outlet axis 318 in at least one direction. In some embodiments, the inlet axis 316 may have both an angular offset and a dimensional offset from outlet axis 318.[0094| The inlet body wall second end portion 317 defines an inlet body second opening 319. The inlet body 310 is configured to provide exhaust to a downstream component, such as the heater body 330, via the inlet body second opening 319.

[0095] In an example embodiment, the inlet body 310 has an “angled” directional configuration. An “angled” directional configuration refers to an inlet body that receives exhaust in a first direction and provides exhaust in a second direction, different than the first direction. For example, the inlet body 310 is configured to receive exhaust via the inlet body first opening 315 in a first direction (e.g., in an extending direction of the inlet axis 316) and provide exhaust to a downstream component via the inlet body second opening 319 in a second direction (e.g., in an extending direction of the outlet axis 318), different than the first direction.|0096] In some embodiments, the inlet body wall 312 includes an inlet body wall intermediate portion 320 that extends between the inlet body wall first end portion 314 and the inlet body wall second end portion 317. The diameter of the inlet body wall 312 may vary across the inlet body wall intermediate portion 320 such that the diameter of the inlet body wall 312 is the first diameter at the inlet body wall first end portion 314 and the diameter of the inlet body wall 312 is the second diameter at the inlet body wall second end portion 317.]0097] In some embodiments, the heater assembly 300 includes an inlet endcap 322 disposed at the inlet body 310. More specifically, the inlet endcap 322 is coupled to the inlet body 310 at the inlet body wall first end portion 314. The inlet endcap 322 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 322 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 322 is four inches.

[0098] The heater body 330 includes a heater body wall 332. The heater body wall includes an inlet flange 334, a central portion 340, and an outlet flange 346. The inlet flange 334 is disposed at a first end of the heater body 330. The outlet flange 346 is disposed at a second end of the heater body 330, opposite the first end. The central portion 340 extends between the inlet flange 334 and the outlet flange 346. In some embodiments, the inlet flange 334 is contiguous with the central portion 340, and the central portion 340 is contiguous with the outlet flange 346.|0099] The heater body wall inlet flange 334 defines a first heater body opening 335. The heater body 330 is configured to receive exhaust from the inlet body 310 via the first heater body opening 335. The heater body wall inlet flange 334 includes a first inlet flange portion 336 and a second inlet flange portion 338. The heater body wall 332 has a first heater body diameter at the first inlet flange portion 336. In some embodiments, the first heater body diameter at the first inlet flange portion 336 is less than the diameter of the inlet body wall second end portion 317. The first inlet flange portion 336 is disposed proximate the inlet body wall second end portion 317. The inlet body wall second end portion 317 may receive at least a portion of the first inlet flange portion 336 therein. For example, the first inlet flange portion 336 is disposed radially inward from the inlet body wall second end portion 317. In this way, the first inlet flange portion 336 facilitates coupling the heater body 330 to the inlet body 310. The first inlet flange portion 336 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the first inlet flange portion 336 is centered on outlet axis 318. The second inlet flange portion 338 extends radially outward and axially downstream from the first inlet flange portion 336 at a first angle with respect to an extending direction of the first inlet flange portion 336. The second inlet flange portion 338 is contiguous with first inlet flange portion 336.[0100| The heater body wall 332 includes a heater body wall central portion 340. The heater body wall 332 has a second heater body diameter at the central portion 340. The second heater body diameter at the heater body wall central portion 340 is greater than the first heater body diameter. The heater body wall central portion 340 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the heater body wall central portion 340 iscentered on outlet axis 318. The heater body wall central portion 340 is substantially parallel to the first inlet flange portion 336. The heater body wall central portion 340 is contiguous with the second inlet flange portion 338.

[0101] In some embodiments, the heater body wall 332 includes a port portion 341. The port portion 341 is disposed on a first side of the heater body wall 332. The port portion 341 includes an angled heater body wall portion 342 and a port wall portion 343. The angled heater body wall portion 342 extends axially and radially outward from the heater body wall central portion at a fourth angle with respect to the extending direction of the heater body wall central portion. The port wall portion 343 extends axially outward from the angled heater body wall portion 342 and substantially parallel to the heater body wall central portion 340. The port wall portion 343 defines a port opening 344 (e.g., a second heater body opening). The port opening 344 is sized to receive a component, such as an electrical component, as described herein below.|0I02] The heater body wall 332 includes a heater body wall outlet flange 346. The heater body wall outlet flange 346 defines a third heater body opening 347. The heater body 330 is configured to provide exhaust to the outlet body 350 via the third heater body opening 347. The heater body wall outlet flange 346 includes a first outlet flange portion 348 and a second outlet flange portion 349. The first outlet flange portion 348 extends axially and radially outward from the heater body wall central portion 340 at a first angle with respect to an extending direction of the heater body wall central portion 340. The first outlet flange portion 348 is contiguous with the heater body wall central portion 340. The second outlet flange portion 349 extends axially outward from the first outlet flange portion 348. The second outlet flange portion 349 is substantially parallel to the heater body wall central portion 340. The second outlet flange portion 349 is contiguous with the first outlet flange portion 348. The heater body wall 332 has a third heater body diameter at the second outlet flange portion 349. The third heater body diameter at the second outlet flange portion 349 is greater than the first heater body diameter and greater than the second heater body diameter. The second outlet flange portion 349 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the second outlet flange portion 349 is centered on outlet axis 318.

[0103] The outlet body 350 includes an outlet body wall 352. The outlet body wall 352 includes an upstream engagement member 354 and a downstream engagement member 356. The upstream engagement member 354 facilitates coupling the outlet body 350 to the heater body 330. The upstream engagement member 354 defines an outlet body upstream opening 358. The outlet body upstream opening 358 is centered on the outlet axis 318. The outlet body 350 receives exhaust from the heater body 330 via the outlet body upstream opening 358. The downstream engagement member 356 facilitates coupling the outlet body 350 to a downstream component, such as a conduit or another component of the aftertreatment system 103. The downstream engagement member 356 defines an outlet body downstream opening 359. The outlet body downstream opening 359 is centered on the outlet axis 318. The outlet body 350 provides exhaust to a downstream component via the outlet body downstream opening 359.

[0104] The upstream engagement member 354 includes a first upstream engagement member wall portion 360. The first upstream engagement member wall portion 360 is disposed proximate the heater body wall outlet flange 346. The outlet body wall 352 has a first outlet body diameter at the first upstream engagement member wall portion 360. In some embodiments, the first outlet body diameter is less than the third heater body diameter. The heater body wall outlet flange 346 may receive at least a portion of the first upstream engagement member wall portion 360 therein. For example, the first upstream engagement member wall portion 360 is disposed radially inward from the second outlet flange portion 349. In this way, the first upstream engagement member wall portion 360 facilitates coupling the outlet body 350 to the heater body 330. The first upstream engagement member wall portion 360 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the first upstream engagement member wall portion 360 is centered on outlet axis 318.

[0105] The upstream engagement member 354 includes a second upstream engagement member wall portion 362. The second upstream engagement member wall portion 362 extends away from the first upstream engagement member wall portion 360. The outlet body wall 352 has a second outlet body diameter at the second upstream engagement member wall portion 362. In some embodiments, the second outlet body diameter is greater than the first outlet bodydiameter. The second upstream engagement member wall portion 362 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the second upstream engagement member wall portion 362 is centered on outlet axis 318.

[0106] In some embodiments, a first upstream engagement member connecting wall portion 361 extends between the first upstream engagement member wall portion 360 and the second upstream engagement member wall portion 362. The first connecting wall portion 361 extends radially outward from and axially downstream from the first upstream engagement member connecting wall portion 361. The first connecting wall portion 361 is contiguous with the first upstream engagement member wall portion 360 and the second upstream engagement member wall portion 362. The first upstream engagement member connecting wall portion 361 is angled with respect to the extending direction of the first upstream engagement member wall portion 360.|0107] The upstream engagement member 354 includes a third upstream engagement member wall portion 364. The third upstream engagement member wall portion 364 extends away from the second upstream engagement member wall portion 362. The outlet body wall 352 has a third outlet body diameter at the third upstream engagement member wall portion 364. In some embodiments, the third outlet body diameter is greater than the first outlet body diameter and greater than the second outlet body diameter. The third upstream engagement member wall portion 364 extends in a direction that is substantially parallel to the outlet axis 318. In some embodiments, the third upstream engagement member wall portion 364 is centered on outlet axis 318.

[0108] In some embodiments, a second upstream engagement member connecting wall portion 363 extends between the second upstream engagement member wall portion 362 and the third upstream engagement member wall portion 364. The second upstream engagement member connecting wall portion 363 extends radially outward from and axially downstream from the second connecting wall portion 362. The second upstream engagement member connecting wall portion 363 is contiguous with the second upstream engagement member wall portion 362 and the third upstream engagement member wall portion 364. The second upstreamengagement member connecting wall portion 363 is angled with respect to the extending direction of the second upstream engagement member wall portion 362.|0109] The downstream engagement member 356 includes a first downstream engagement member wall portion 366. The first downstream engagement member wall portion 366 extends radially outward and axially downstream from the third upstream engagement member wall portion 364. The first downstream engagement member wall portion 366 is continuous with the first downstream engagement member wall portion 366.

[0110] The downstream engagement member 356 includes a second downstream engagement member wall portion 367. The second downstream engagement member wall portion 367 extends radially inward and axially downstream from the first downstream engagement member wall portion 366. The second downstream engagement member wall portion 367 is continuous with the first downstream engagement member wall portion 366.

[0111] The first downstream engagement member wall portion 366 and the second downstream engagement member wall portion 367 cooperate to define a downstream engagement surface 368. The downstream engagement surface 368 facilitates coupling the heater assembly 300 to a downstream component, such as a conduit or another component of the aftertreatment system 103.[0112| The heater assembly 300 includes a heat shield 370 disposed around the heater body 330. The heat shield 370 is disposed around at least a portion of the outlet body 350. The heat shield 370 is disposed around at least a portion of the inlet body 310. The heat shield 370 is configured to at least partially thermally isolate an inner volume of the heat shield 370 from a volume outside the heat shield 370.[0U3| In some embodiments, the heat shield 370 includes a heat shield first portion 372 and a heat shield second portion 374. The heat shield first portion 372 is disposed around at least a portion of the inlet body 310 and at least a portion of the heater body 330. In some embodiments, the heat shield first portion 372 is coupled to at least one of the inlet body 310 and / or the heater body 330. The heat shield second portion 374 is disposed around at least aportion of the heater body 330 and at least a portion of the outlet body 350. In some embodiments, the heat shield first portion 372 is coupled to at least one of the heater body 330 and / or the outlet body 350. In some embodiments, the heat shield first portion 372 is coupled to the heat shield second portion 374. In an example embodiment, the heat shield 370 includes a heat shield flange 376. The heat shield flange 376 facilities coupling at least a portion of the heat shield 370, such as the heat shield second portion 374, to the outlet body 350. For example, the heat shield flange 376 may couple to the second upstream engagement member wall portion 362. In this way the upstream engagement member 354 facilities coupling the outlet body 350 to the heat shield 370.[0114| In other embodiments, the heat shield 370 incudes only one of the heat shield first portion 372 or the heat shield second portion 374. In these embodiments, the heat shield 370 is a single, contiguous component. For example, the heat shield 370 may be disposed around at least a portion of the inlet body 310, around the heater body 330, and around at least a portion of the outlet body 350.[0U5| In some embodiments, the heater assembly 300 includes a heater 380. As shown in FIG. 7, the heater 380 is disposed within a heater body volume 381 defined by the heater body wall 332. The heater 380 is configured to heat the exhaust flowing through the heater assembly 300. The heater 380 is an electric heater that is configured to convert electrical energy into thermal energy. In various embodiments, the heater 380 is an electric heater (e.g., resistance heaters, heating elements, etc.) and not burners (e.g., combustion heaters, etc.).[0116| The heater 380 is coupled to a power source (e.g., an electrical system of the internal combustion engine system 100, etc.) via wires (e.g., electrical wires, etc.). The wires are routed from outside of the heater body 330 into the heater body and to the heater 380. In some embodiments, the wires are routed through the heater body 330 at a location proximate the heater 380 and to the heater 380. In some embodiments, the heater 380 includes one or more heating components configured to generate heat. The heating components may be made of a nichrome material or a ceramic material. Each of the one or more heating components may be positioned to heat exhaust flowing through the heater body 330.

[0117] The heater assembly 300 includes one or more electrode wires 382. The one or more electrode wires 382 extend through the heater body wall 332 and into the heater body 330. The electrode wires 382 are electrically coupled to the heater 380. The electrode wires 382 may selectively provide electrical energy to the heater (e.g., DC power, DC power provided via a pulse wave modulation signal, AC power, etc.).[0118| In some embodiments, the heater body 330 may have a predetermined “internal configuration.” As used herein an “internal configuration” refers to an arrangement or characteristics of the internal components of a body or assembly, such as the heater body 330. For example, the internal configuration of the heater body 330 may vary based on a type, configuration, or other characteristics of a heater 380 positioned in the heater body 330.

[0119] In some embodiments, the heater 380 has a first heater configuration that is configured to output a first amount of heat energy (e.g., British thermal units (BTUs), kilowatt hours, etc.) or power (e g., BTU per hour, kilowatts). In other embodiments, the heater 380 has a second heater configuration that is configured to output a second amount of heat or power, different than the first amount of heat energy or power. Thus, the internal configuration of the heater body 330 may change depending on the configuration of the heater 380 positioned within the heater body 330.

[0120] In some embodiments, the heater assembly 300 includes a mounting bracket 500. The mounting bracket is configured to support the one or more electrode wires 382. The mounting bracket 500 is described in greater detail herein with respect to Figure 6.]0121] Referring now to Figure 5, a side view of a heater assembly 300 in another configuration is shown. In the configuration shown in Figure 5, the heater assembly 300 includes a second inlet body 410, the heater body 330, the outlet body 350, and the heat shield 370.

[0122] The second inlet body 410 is substantially similar to the inlet body 310 of Figures 3 and4. For example, the inlet body 410 includes an inlet body wall 412. The inlet body wall 412includes an inlet body wall first end portion 414 (e.g., an inlet portion) and a second end portion 417 (e.g., an outlet portion).|0123] The inlet body wall first end portion 414 has a first diameter. The second inlet body 410 differs from the inlet body 310 in that the first diameter of the inlet body wall first end portion 414 is greater than the first diameter of the inlet body wall first end portion 314. The inlet body wall first end portion 414 of the second inlet body 410 is sized to accommodate a different (e.g., larger) upstream component compared to the inlet body wall first end portion 314 of the first inlet body 310.|01 4] The inlet body wall first end portion 414 is centered on an inlet axis 316 of the heater assembly 300 (e.g., the inlet axis 316 extends through a center point of the inlet body wall first end portion 414, etc.). The inlet body wall first end portion 414 defines an inlet body first opening 415. In an example embodiment, the inlet body 410 has an angled directional configuration. In some embodiments, the inlet axis 316 intersects the outlet axis 318. In other embodiments, the inlet axis 316 may also feature a dimensional offset from the outlet axis 318. For example, the inlet axis 316 may be spaced away from the outlet axis 318 in at least one direction. In some embodiments, the inlet axis 316 may have both an angular offset and a dimensional offset from outlet axis 318.

[0125] The inlet body wall second end portion 417 is the same as inlet body wall second end portion 317. The inlet body 410 may also include an inlet body wall intermediate portion 418 that extends between the inlet body wall first end portion 414 and the inlet body wall second end portion 417. The inlet body wall intermediate portion 418 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 418 is structured to accommodate the larger diameter of the inlet body wall first end portion 414.|0126] In some embodiments, the heater assembly 300 includes an inlet endcap 419 disposed at the inlet body wall first end portion 414. More specifically, the inlet endcap 419 is coupled to the inlet body 410 at the inlet body wall first end portion 414. The inlet endcap 419 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or othercomponent of the aftertreatment system 103. The inlet endcap 419 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 419 is five inches.

[0127] Advantageously, the inlet body 410 includes a larger inlet body wall first end portion 414 to facilitate coupling the inlet body 410 to a larger upstream component (e.g., via the larger inlet endcap 419). Furthermore, because the inlet body wall second end portion 417 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0128] Referring now to Figures 7 and 8, the heater assembly 300 is shown in another configuration. In the configuration shown in Figures 7 and 8, the heater assembly 300 includes a third inlet body 420, the heater body 330, the outlet body 350, and a heat shield 470.|0129] The third inlet body 420 is substantially similar to the first inlet body 310 of Figures 3 and 4. For example, the third inlet body 420 includes an inlet body wall 422. The inlet body wall 422 includes an inlet body wall first end portion 424 (e.g., an inlet portion) and a second end portion 427 (e.g., an outlet portion).[0130| The inlet body wall first end portion 424 has a first diameter. The first diameter of the inlet body wall first end portion 424 is substantially similar to or the same as the first diameter of the inlet body wall first end portion 314.|0131] The inlet body 420 differs from the inlet body 310 in that the inlet body wall first end portion 424 is centered on central axis 425 of the heater assembly 300 (e.g., the central axis 425 extends through a center point of the inlet body wall first end portion 424, etc.). The inlet body wall first end portion 424 defines an inlet body first opening 426.[0132 { The inlet body 420 includes the inlet body wall second end portion 427. The inlet body wall second end portion 427 is the same as the inlet body wall second end portion 317 of the first inlet body 310 and / or the inlet body wall second end portion 417 of the second inlet body410. The inlet body wall second end portion 427 is centered on the central axis 425. In this way the third inlet body 420 receives and provides exhaust in an extending direction of the central axis 425. That is the third inlet body 420 has an “axial” directional configuration. An “axial” directional configuration refers to an inlet body that receives exhaust in a first direction and provides exhaust in the first direction. For example, the exhaust flows along the central axis 425 of the heater assembly 300.

[0133] The inlet body 420 may also include an inlet body wall intermediate portion 428 that extends between the inlet body wall first end portion 424 and the inlet body wall second end portion 427. The inlet body wall intermediate portion 428 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 428 is structured to accommodate the axial configuration of the inlet body 420.

[0134] In some embodiments, the heater assembly 300 includes an inlet endcap 429 disposed at the inlet body 420. More specifically, the inlet endcap 429 is coupled to the inlet body 420 at the inlet body wall first end portion 424. The inlet endcap 429 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 429 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 429 is four inches.|(H 35] The heater assembly 300 includes a heat shield 470 disposed around the heater body 330. The heat shield 470 is disposed around at least a portion of the outlet body 350. The heat shield 470 is disposed around at least a portion of the inlet body 420. The heat shield 470 is configured to at least partially thermally isolate an inner volume of the heat shield 470 from a volume outside the heat shield 470.

[0136] In some embodiments, the heat shield 470 includes a heat shield body 478. The heat shield body 478 is disposed around at least a portion of the inlet body 420, around the heater body 330, and around at least a portion of the outlet body 350. In some embodiments, the heat shield body 478 is coupled to at least one of the inlet body 420, the heater body 330, and / or the outlet body 350. In an example embodiment, the heat shield 370 includes a heat shield flange476. The heat shield flange 476 facilities coupling at least a portion of the heat shield 470, such as the heat shield body 478, to the outlet body 350. For example, the heat shield flange 476 may couple to the second upstream engagement member wall portion 362. In this way the upstream engagement member 354 facilities coupling the outlet body 350 to the heat shield 470.[0137| Advantageously, the inlet body 420 has an axial configuration allowing exhaust to flow through the heater assembly 300 parallel to the central axis 425. Furthermore, because the inlet body wall second end portion 427 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0138] Referring now to Figure 9, a side view of a heater assembly 300 in another configuration is shown. In the configuration shown in Figure 9, the heater assembly 300 includes a fourth inlet body 430, the heater body 330, the outlet body 350, and the heat shield 470.

[0139] The fourth inlet body 430 is substantially similar to the third inlet body 420 of Figures 7 and 8. For example, the fourth inlet body 430 includes an inlet body wall 432. The inlet body wall 432 includes an inlet body wall first end portion 434 (e.g., an inlet portion) and a second end portion 437 (e.g., an outlet portion).

[0140] The inlet body wall first end portion 434 has a first diameter. The fourth inlet body 430 differs from the third inlet body 420 in that the first diameter of the inlet body wall first end portion 434 is greater than the first diameter of the inlet body wall first end portion 424. The inlet body wall first end portion 434 of the fourth inlet body 430 is sized to accommodate a different (e.g., larger) upstream component compared to the inlet body wall first end portion 424 of the third inlet body 420.|<>141] The inlet body wall first end portion 434 is centered on the center axis 425 of the heater assembly 300 (e.g., the center axis 425 extends through a center point of the inlet body wallfirst end portion 434, etc.). The inlet body wall first end portion 434 defines an inlet body first opening 436. In this way the fourth inlet body 430 receives and provides exhaust in an extending direction of the central axis 425. That is, the fourth inlet body 430 has an axial directional configuration, where the exhaust flows along the central axis 425 of the heater assembly 300.[01421 The inlet body wall second end portion 437 is the same as inlet body wall second end portion 427. The inlet body 430 may also include an inlet body wall intermediate portion 438 that extends between the inlet body wall first end portion 434 and the inlet body wall second end portion 437. The inlet body wall intermediate portion 438 is substantially similar to the inlet body wall intermediate portion 428 except that the inlet body wall intermediate portion 438 is structured to accommodate the larger diameter of the inlet body wall first end portion 434.|0143] In some embodiments, the heater assembly 300 includes an inlet endcap 439 disposed at the inlet body wall first end portion 434. More specifically, the inlet endcap 439 is coupled to the inlet body 430 at the inlet body wall first end portion 434. The inlet endcap 439 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 439 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 439 is five inches.

[0144] Advantageously, the inlet body 430 includes a larger inlet body wall first end portion 434 to facilitate coupling the inlet body 430 to a larger upstream component (e.g., via the larger inlet endcap 419). Furthermore, because the inlet body wall second end portion 437 is the same as inlet body wall second end portion 427, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0145] Figure 10 is a cross-sectional view of a heater assembly 300, shown in another configuration. In the configuration shown in Figure 10, the heater assembly 300 includes a fifth inlet body 450, the heater body 330, the outlet body 350, and the heat shield 370.

[0146] The fifth inlet body 450 includes an inlet body wall 452. The inlet body wall 452 includes an inlet body wall first end portion 454 (e.g., an inlet portion) and a second end portion 457 (e g., an outlet portion).[0147| The inlet body wall first end portion 454 is centered on an inlet axis 316 of the heater assembly 300 (e.g., the inlet axis 316 extends through a center point of the inlet body wall first end portion 454, etc.). The inlet body wall first end portion 454 defines an inlet body first opening 455.

[0148] In some embodiments, the first diameter of the inlet body wall first end portion 454 of the fifth inlet body 450 is the same as the first diameter of the inlet body wall first end portion 314 of the first inlet body 310. In other embodiments, first diameter of the inlet body wall first end portion 454 of the fifth inlet body 450 is the same as the first diameter of the inlet body wall first end portion 414 of the second inlet body 410.

[0149] The inlet body wall second end portion 457 has a second diameter. In some embodiments, the second diameter is different than the first diameter. For example, the second diameter may be larger than the first diameter. The inlet body wall second end portion 457 is centered on an outlet axis 318 of the heater assembly 300 (e.g., the outlet axis 318 extends through a center point of the inlet body wall second end portion 457, etc.). The outlet axis 318 is angled with respect to the inlet axis 316. For example, an angle between the inlet axis 316 and the outlet axis 18 is greater than 0° and less than 180° (e.g., an angular offset of between 0° and 180°). As shown in Figure 10, the angle between the inlet axis 316 and the outlet axis 318 is 90°. In some embodiments, and as shown, the inlet axis 316 intersects the outlet axis 318. In other embodiments, the inlet axis 316 may also feature a dimensional offset from the outlet axis 318. For example, the inlet axis 316 may be spaced away from the outlet axis 318 in at least one direction. In some embodiments, the inlet axis 316 may have both an angular offset and a dimensional offset from outlet axis 318.

[0150] The inlet body wall second end portion 457 defines an inlet body second opening 459. The inlet body 450 is configured to provide exhaust to a downstream component, such as the heater body 330, via the inlet body second opening 459.

[0151] In some embodiments, the inlet body wall 452 includes an inlet body wall intermediate portion 458 that extends between the inlet body wall first end portion 454 and the inlet body wall second end portion 457. The diameter of the inlet body wall 452 may vary across the inlet body wall intermediate portion 458 such that the diameter of the inlet body wall 452 is the first diameter at the inlet body wall first end portion 454 and the diameter of the inlet body wall 452 is the second diameter at the inlet body wall second end portion 457.

[0152] The inlet body 450 includes an inner body 460 disposed at least partially within the inlet body wall 452. The inner body 460 includes an inner body wall 462 and an inner body end cap 468.

[0153] The inner body wall 462 includes an inner body wall upstream portion 464 and an inner body wall downstream portion 466. The inner body wall upstream portion 464 is contiguous with the inner body wall downstream portion 466. The inner body wall upstream portion 464 has a first diameter. The first diameter of the inner body wall upstream portion 464 is smaller than the first diameter of the inlet body wall first end portion 454. At least a portion of the inner body wall upstream portion 464 extends through the opening 455, such that at least a portion of the inner body wall 462 extends outside of the inlet body wall 452. The inner body wall upstream portion 464 defines an inner body opening 465. The inner body 460 is configured to receive exhaust from an upstream component via the inner body opening 465. The inner body wall downstream portion 466 is disposed within the inlet body wall 452.[01541 The inner body wall 462 defines one or more openings 467 therethrough. More specifically, the inner body wall downstream portion 466 defines one or more openings 467 therethrough. The one or more openings 467 are directed radially through the inner body wall downstream portion 466. In an example embodiment, the one or more openings 467 are disposed in a pattern around a circumference of the inner body wall 462 and axially along the length of the inner body wall downstream portion 466. The one or more openings 467 allowexhaust to flow therethrough. More specifically, exhaust received by the inner body 460 (e.g., via the inner body opening 465) flows out of the inner body 460 (e.g., into the inlet body 450) via the one or more openings 467. Advantageously, as the exhaust flows through the one or more openings 467, the exhaust is “straightened.” As used herein “straightening” a flow of a fluid, such as exhaust, refers to a process by which turbulent flow in the fluid is substantially reduced. In some embodiments, straightening a flow of a fluid results in laminar flow. The inner body 460 is structured to straighten a flow of exhaust flowing therethrough by causing the exhaust to flow through the one or more openings 467.

[0155] The inner body end cap 468 is disposed at an axial end of the inner body wall downstream portion 466, opposite the inner body wall upstream portion 464. The inner body end cap 468 defines an end of the inner body 460. The inner body end cap 468 substantially prevents exhaust from flowing axially through the inner body 460. In some embodiments, the inner body end cap 468 contacts the inlet body wall 452. In other embodiments, the inner body end cap 468 extends through an opening of the inlet body wall 452.[0156| In an example embodiment, the inlet body 450 has an angled directional configuration. The inlet body wall first end portion 454 has a first diameter. In an example embodiment, the inlet body 450 is configured to receive exhaust via the inner body opening 465 of the inner body 460 in a first direction (e.g., in an extending direction of the inlet axis 316). The exhaust flows through the one or more openings 467 in the inner body 460 to straighten the flow of the exhaust. The inlet body 450 then provides the exhaust to a downstream component via the inlet body second opening 459 in a second direction (e.g., in an extending direction of the outlet axis 318), different than the first direction.|0157] The inlet body wall second end portion 457 is the same as inlet body wall second end portion 317. The inlet body 450 may also include the inlet body wall intermediate portion 458 that extends between the inlet body wall first end portion 454 and the inlet body wall second end portion 457. The inlet body wall intermediate portion 458 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 458 is structured to accommodate the inner body 460.

[0158] In some embodiments, the heater assembly 300 includes an inlet endcap 480 disposed at the inlet body 450. More specifically, the inlet endcap 480 is coupled to the inner body 460 at the inner body wall upstream portion 464. The inlet endcap 480 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 480 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 480 is four inches. In another example embodiment, the outer diameter of the inlet endcap 480 is five inches.

[0159] Advantageously, the inlet body 450 includes the inner body 460 to facilitate straightening the flow of exhaust through the inlet body 450. Additionally, the inlet body 450 may include an inlet endcap 480 that is sized to accommodate an upstream component. For example, the first diameter of the inlet body wall first end portion 454 of the fifth inlet body 450, the diameter of the inner body wall upstream portion 464, and / or the diameter of the inlet endcap 480 may be sized to accommodate an upstream component. In this way, the inlet body 450 facilitates coupling heater assembly 300 to an upstream component. Furthermore, because the inlet body wall second end portion 457 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0160] Referring now to Figure 11, the heater assembly 300 is shown in another configuration. In the configuration shown in Figure 11, the heater assembly 300 includes a sixth inlet body 490, the heater body 330, and the outlet body 350. In some embodiments, the heater assembly may also include the heat shield 470, described herein above.

[0161] The sixth inlet body 490 is substantially similar to the third inlet body 420 of Figures 7 and 8. For example, the sixth inlet body 490 includes an inlet body wall 492. The inlet body wall 492 includes an inlet body wall first end portion 494 (e.g., an inlet portion) and a second end portion 497 (e.g., an outlet portion).

[0162] The inlet body wall first end portion 494 has a first diameter. The first diameter of the inlet body wall first end portion 494 of the sixth inlet body 490 is larger than the first diameter of the inlet body wall first end portion 424 of the third inlet body 420 and larger than the inlet body wall first end portion 434 of the fourth inlet body 430.[01631 The inlet body wall first end portion 494 is centered on the center axis 425 of the heater assembly 300 (e.g., the center axis 425 extends through a center point of the inlet body wall first end portion 494, etc.). The inlet body wall first end portion 494 defines an inlet body first opening 496.|01 4] The inlet body 490 includes the inlet body wall second end portion 497. The inlet body wall second end portion 497 is the same as inlet body wall second end portion 427. The inlet body wall second end portion 497 is centered on the central axis 425. In this way the sixth inlet body 490 receives and provides exhaust in an extending direction of the central axis 425. That is the sixth inlet body 490 has an axial configuration.|0165] The inlet body 490 may also include an inlet body wall intermediate portion 498 that extends between the inlet body wall first end portion 494 and the inlet body wall second end portion 497. The inlet body wall intermediate portion 498 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 498 is structured to accommodate the axial configuration of the inlet body 490 and the larger diameter of the inlet body wall first end portion 494.|01 6] In an example embodiment, the inlet body wall first end portion 494 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. In an example embodiment, the first diameter of the inlet body wall first end portion 494 is sized to facilitate coupling the heater assembly 300 to another heater assembly 300. In an example embodiment, the outer diameter of the inlet body wall first end portion 494 is eight inches.|01 7] Advantageously, the inlet body 490 has an axial configuration allowing exhaust to flow through the heater assembly 300 parallel to the central axis 425. Additionally, because the firstdiameter of the inlet body wall first end portion 494 is sized to facilitate coupling the heater assembly 300 to another heater assembly 300, the inlet body 490 advantageously enables the heater assembly 300 to be provided in series (e.g., when the sixth inlet body 490 is provided in the downstream heater assembly 300). Furthermore, because the inlet body wall second end portion 427 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0168] Figures 12 and 13 are a side view and a cross-sectional view of a heater assembly 300, shown in another configuration. In the configuration shown in Figures 12 and 13, the heater assembly 300 includes a seventh inlet body 710, the heater body 330, the outlet body 350, and the heat shield 370.(0169 As shown in Figure 13, the seventh inlet body 710 includes an inlet body wall 712. The inlet body wall 712 includes an inlet body wall first end portion 714 (e.g., an inlet portion) and a second end portion 717 (e.g., an outlet portion).(0170] The inlet body wall first end portion 714 is centered on an inlet axis 316 of the heater assembly 300 (e.g., the inlet axis 316 extends through a center point of the inlet body wall first end portion 714, etc.). The inlet body wall first end portion 714 defines an inlet body first opening 715.(0171] In some embodiments, a first diameter of the inlet body wall first end portion 714 of the seventh inlet body 710 is the same or approximately the same as the first diameter of the inlet body wall first end portion 314 of the first inlet body 310. The first diameter of the inlet body wall first end portion 714 of the seventh inlet body 710 is the same or approximately the same as the first diameter of the inlet body wall first end portion 454 of the fifth inlet body 450.(0172] The inlet body wall second end portion 717 has a second diameter. In some embodiments, the second diameter is different than the first diameter. For example, the second diameter may be larger than the first diameter. The inlet body wall second end portion 717 iscentered on an outlet axis 318 of the heater assembly 300 (e.g., the outlet axis 318 extends through a center point of the inlet body wall second end portion 717, etc.). The outlet axis 318 is angled with respect to the inlet axis 316. For example, an angle between the inlet axis 316 and the outlet axis 318 is greater than 0° and less than 180° (e.g., an angular offset of between 0° and 180°). As shown in Figures 12 and 13, the angle between the inlet axis 316 and the outlet axis 318 is 90°. In some embodiments, and as shown, the inlet axis 316 intersects the outlet axis 318. In other embodiments, the inlet axis 316 may also feature a dimensional offset from the outlet axis 318. For example, the inlet axis 316 may be spaced away from the outlet axis 318 in at least one direction. In some embodiments, the inlet axis 316 may have both an angular offset and a dimensional offset from outlet axis 318.

[0173] As shown in Figure 13, the inlet body wall second end portion 717 defines an inlet body second opening 719. The inlet body 710 is configured to provide exhaust to a downstream component, such as the heater body 330, via the inlet body second opening 719.|0174] In some embodiments, the inlet body wall 712 includes an inlet body wall intermediate portion 718 that extends between the inlet body wall first end portion 714 and the inlet body wall second end portion 717. The diameter of the inlet body wall 712 may vary across the inlet body wall intermediate portion 718 such that the diameter of the inlet body wall 712 is the first diameter at the inlet body wall first end portion 714 and the diameter of the inlet body wall 712 is the second diameter at the inlet body wall second end portion 717.

[0175] The inlet body 710 includes an inner body 720 disposed at least partially within the inlet body wall 712. The inner body 720 includes an inner body wall 722 and an inner body end cap 728.

[0176] The inner body wall 722 includes an inner body wall upstream portion 724 and an inner body wall downstream portion 726. The inner body wall upstream portion 724 is contiguous with the inner body wall downstream portion 726. The inner body wall upstream portion 724 has a first diameter. The first diameter of the inner body wall upstream portion 724 is smaller than the first diameter of the inlet body wall first end portion 714. The first diameter of theinner body wall upstream portion 724 is similar to or approximately similar to the first diameter of the inlet body wall first end portion 314 of the first inlet body 310.|0177] At least a portion of the inner body wall upstream portion 724 is positioned upstream of the opening 715, such that at least a portion of the inner body wall 722 extends outside of the inlet body wall 712. The inner body wall upstream portion 724 defines an inner body opening 725. The inner body 720 is configured to receive exhaust from an upstream component via the inner body opening 725.

[0178] The inner body wall downstream portion 726 is at least partially disposed within the inlet body wall 712. The inner body wall downstream portion 726 has a second diameter. The second diameter of the inner body wall downstream portion 726 is larger than the first diameter of the inner body wall upstream portion 724. The second diameter of the inner body wall downstream portion 726 is smaller than the first diameter of the inlet body wall first end portion 714.

[0179] The inner body wall 722 defines one or more openings 727 therethrough. More specifically, the inner body wall downstream portion 726 defines the one or more openings 727 therethrough. The one or more openings 727 are directed radially through the inner body wall downstream portion 726. In an example embodiment, the one or more openings 727 are disposed in a pattern around a circumference of the inner body wall 722 and axially along the length of the inner body wall downstream portion 726. The one or more openings 727 allow exhaust to flow therethrough. More specifically, exhaust received by the inner body 720 (e.g., via the inner body opening 725) flows out of the inner body 720 (e.g., into the inlet body 710) via the one or more openings 727. Advantageously, as the exhaust flows through the one or more openings 727, the exhaust is straightened, such that the turbulent flow in the exhaust gas is substantially reduced. The inner body 720 is structured to straighten a flow of exhaust flowing therethrough by causing the exhaust to flow through the one or more openings 727.[0180[ The inner body wall 722 includes an inner body wall intermediate portion 729 that extends between the inner body wall upstream portion 724 and the inner body wall downstream portion 726. The diameter of the inner body wall 722 may vary across the inner body wallintermediate portion 729 such that the diameter of the inner body wall 722 is the first diameter at the inner body wall upstream portion 724 and the diameter of the inner body wall 722 is the second diameter at the inner body wall downstream portion 726.

[0181] The inner body end cap 728 is disposed at an axial end of the inner body wall downstream portion 726, opposite the inner body wall upstream portion 724. The inner body end cap 728 defines an end of the inner body 720. The inner body end cap 728 substantially prevents exhaust from flowing axially through the inner body 720. In some embodiments, the inner body end cap 728 contacts the inlet body wall 722. In other embodiments, the inner body end cap 728 extends through an opening of the inlet body wall 722.

[0182] In an example embodiment, the inlet body 710 has an angled directional configuration. The inner body wall upstream portion 724 has a first diameter. In an example embodiment, the inlet body 710 is configured to receive exhaust via the inner body opening 725 of the inner body 720 in a first direction (e g., in an extending direction of the inlet axis 316). The exhaust flows through the one or more openings 727 in the inner body 720 to straighten the flow of the exhaust. The inlet body 720 then provides the exhaust to a downstream component via the inlet body second opening 719 in a second direction (e.g., in an extending direction of the outlet axis 318), different than the first direction.10183] The inlet body wall second end portion 717 is the same as inlet body wall second end portion 317. The inlet body 710 may also include the inlet body wall intermediate portion 718 that extends between the inlet body wall first end portion 714 and the inlet body wall second end portion 717. The inlet body wall intermediate portion 718 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 718 is structured to accommodate the inner body 720.

[0184] In some embodiments, the heater assembly 300 includes an inlet endcap 730 disposed at the inlet body 710. More specifically, the inlet endcap 730 is coupled to the inner body 720 at the inner body wall upstream portion 724. The inlet endcap 730 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 730 has an outer diameter that is sized toaccommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 730 is four inches.|0I 85] Advantageously, the inlet body 710 includes the inner body 720 to facilitate straightening the flow of exhaust through the inlet body 710. Additionally, the inlet body 710 may include an inlet endcap 730 that is sized to accommodate an upstream component. For example, the first diameter of the inlet body wall first end portion 714 of the seventh inlet body 710, the diameter of the inner body wall upstream portion 724, and / or the diameter of the inlet endcap 730 may be sized to accommodate an upstream component. In this way, the inlet body 710 facilitates coupling the heater assembly 300 to an upstream component. Furthermore, because the inlet body wall second end portion 717 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0186] In some embodiments, the heater assembly 300 includes a mounting bracket 600. The mounting bracket 600 is configured to support the one or more electrode wires 382. The mounting bracket 600 is described in greater detail herein with respect to Figures 16, 17, 20, and 21.|(H 87] Figures 14 and 15 are a side view and a cross-sectional view of a heater assembly 300, shown in another configuration. In the configuration shown in Figures 14 and 15, the heater assembly 300 includes an eighth inlet body 740, the heater body 330, the outlet body 350, and the heat shield 370.

[0188] As shown in Figure 15, the eighth inlet body 740 includes an inlet body wall 742. In some embodiments, the inlet body wall 742 is substantially similar to or the same as the inlet body wall 742 of the eighth inlet body 740. The inlet body wall 742 includes an inlet body wall first end portion 744 (e.g., an inlet portion) and a second end portion 747 (e.g., an outlet portion).

[0189] The inlet body wall first end portion 744 is centered on an inlet axis 316 of the heater assembly 300 (e.g., the inlet axis 316 extends through a center point of the inlet body wall first end portion 744, etc.). The inlet body wall first end portion 744 defines an inlet body first opening 745.[0190| In some embodiments, a first diameter of the inlet body wall first end portion 744 of the eighth inlet body 740 is the same or approximately the same as the first diameter of the inlet body wall first end portion 314 of the first inlet body 310. The first diameter of the inlet body wall first end portion 744 of the eighth inlet body 740 is the same or approximately the same as the first diameter of the inlet body wall first end portion 454 of the fifth inlet body 450.

[0191] The inlet body wall second end portion 747 has a second diameter. In some embodiments, the second diameter is different than the first diameter. For example, the second diameter may be larger than the first diameter. The inlet body wall second end portion 747 is centered on an outlet axis 318 of the heater assembly 300 (e g., the outlet axis 318 extends through a center point of the inlet body wall second end portion 747, etc.). The outlet axis 318 is angled with respect to the inlet axis 316. For example, an angle between the inlet axis 316 and the outlet axis 318 is greater than 0° and less than 180° (e.g., an angular offset of between 0° and 180°). As shown in Figures 14 and 15, the angle between the inlet axis 316 and the outlet axis 318 is 90°. In some embodiments, and as shown, the inlet axis 316 intersects the outlet axis 318. In other embodiments, the inlet axis 316 may also feature a dimensional offset from the outlet axis 318. For example, the inlet axis 316 may be spaced away from the outlet axis 318 in at least one direction. In some embodiments, the inlet axis 316 may have both an angular offset and a dimensional offset from outlet axis 318.|01 2] As shown in Figure 15, the inlet body wall second end portion 747 defines an inlet body second opening 749. The inlet body 740 is configured to provide exhaust to a downstream component, such as the heater body 330, via the inlet body second opening 749.

[0193] In some embodiments, the inlet body wall 742 includes an inlet body wall intermediate portion 748 that extends between the inlet body wall first end portion 744 and the inlet body wall second end portion 747. The diameter of the inlet body wall 742 may vary across the inletbody wall intermediate portion 748 such that the diameter of the inlet body wall 742 is the first diameter at the inlet body wall first end portion 744 and the diameter of the inlet body wall 742 is the second diameter at the inlet body wall second end portion 747.

[0194] The inlet body 740 includes an inner body 750 disposed at least partially within the inlet body wall 742. The inner body 750 includes an inner body wall 752 and an inner body end cap 758.[01951 The inner body wall 752 includes an inner body wall upstream portion 754 and an inner body wall downstream portion 756. The inner body wall upstream portion 754 is contiguous with the inner body wall downstream portion 756. The inner body wall upstream portion 754 has a first diameter. The first diameter of the inner body wall upstream portion 754 is smaller than the first diameter of the inlet body wall first end portion 744. The first diameter of the inner body wall upstream portion 754 is similar to or approximately similar to the first diameter of the inlet body wall first end portion 414 of the second inlet body 410.

[0196] At least a portion of the inner body wall upstream portion 754 is positioned upstream of the opening 745, such that at least a portion of the inner body wall 752 extends outside of the inlet body wall 742. The inner body wall upstream portion 754 defines an inner body opening 755. The inner body 750 is configured to receive exhaust from an upstream component via the inner body opening 755.[0197[ The inner body wall downstream portion 756 is at least partially disposed within the inlet body wall 742. The inner body wall downstream portion 756 has a second diameter. The second diameter of the inner body wall downstream portion 756 is the same as or approximately the same as the first diameter of the inner body wall upstream portion 754. The second diameter of the inner body wall downstream portion 756 is smaller than the first diameter of the inlet body wall first end portion 744.

[0198] The inner body wall 752 defines one or more openings 757 therethrough. More specifically, the inner body wall downstream portion 756 defines the one or more openings 757 therethrough. The one or more openings 757 are directed radially through the inner body walldownstream portion 756. In an example embodiment, the one or more openings 757 are disposed in a pattern around a circumference of the inner body wall 752 and axially along the length of the inner body wall downstream portion 756. The one or more openings 757 allow exhaust to flow therethrough. More specifically, exhaust received by the inner body 750 (e.g., via the inner body opening 755) flows out of the inner body 750 (e.g., into the inlet body 740) via the one or more openings 757. Advantageously, as the exhaust flows through the one or more openings 757, the exhaust is straightened, such that the turbulent flow in the exhaust gas is substantially reduced. The inner body 750 is structured to straighten a flow of exhaust flowing therethrough by causing the exhaust to flow through the one or more openings 757.[0199| The inner body wall 752 includes an inner body wall intermediate portion 759 that extends between the inner body wall upstream portion 754 and the inner body wall downstream portion 756. The diameter of the inner body wall intermediate portion 759 is the same as or substantially the same as the first diameter of the inner body wall upstream portion 754 and the second diameter of the inner body wall downstream portion 756.[0200| The inner body end cap 758 is disposed at an axial end of the inner body wall downstream portion 756, opposite the inner body wall upstream portion 754. The inner body end cap 758 defines an end of the inner body 750. The inner body end cap 758 substantially prevents exhaust from flowing axially through the inner body 750. In some embodiments, the inner body end cap 758 contacts the inlet body wall 752. In other embodiments, the inner body end cap 758 extends through an opening of the inlet body wall 752.[02011 In an example embodiment, the inlet body 740 has an angled directional configuration. The inner body wall upstream portion 754 has a first diameter. In an example embodiment, the inlet body 740 is configured to receive exhaust via the inner body opening 755 of the inner body 750 in a first direction (e.g., in an extending direction of the inlet axis 316). The exhaust flows through the one or more openings 757 in the inner body 750 to straighten the flow of the exhaust. The inlet body 750 then provides the exhaust to a downstream component via the inlet body second opening 749 in a second direction (e.g., in an extending direction of the outlet axis 318), different than the first direction.

[0202] The inlet body wall second end portion 747 is the same as inlet body wall second end portion 317. The inlet body 740 may also include the inlet body wall intermediate portion 748 that extends between the inlet body wall first end portion 744 and the inlet body wall second end portion 747. The inlet body wall intermediate portion 748 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 748 is structured to accommodate the inner body 750.

[0203] In some embodiments, the heater assembly 300 includes an inlet endcap 760 disposed at the inlet body 740. More specifically, the inlet endcap 760 is coupled to the inner body 750 at the inner body wall upstream portion 754. The inlet endcap 760 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 760 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 760 is five inches.|0204] Advantageously, the inlet body 740 includes the inner body 750 to facilitate straightening the flow of exhaust through the inlet body 740. Additionally, the inlet body 740 may include an inlet endcap 760 that is sized to accommodate an upstream component. For example, the first diameter of the inlet body wall first end portion 744 of the eighth inlet body 740, the diameter of the inner body wall upstream portion 754, and / or the diameter of the inlet endcap 760 may be sized to accommodate an upstream component. In this way, the inlet body 740 facilitates coupling the heater assembly 300 to an upstream component. Furthermore, because the inlet body wall second end portion 747 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0205] In some embodiments, the heater assembly 300 includes a mounting bracket 600. The mounting bracket 600 is configured to support the one or more electrode wires 382. Themounting bracket 600 is described in greater detail herein with respect to Figures 16, 17, 20, and 21.|0206] Referring now to Figures 18 and 19, the heater assembly 300 is shown in another configuration. In the configuration shown in Figures 18 and 19, the heater assembly 300 includes a ninth inlet body 810, the heater body 330, the outlet body 350, and a heat shield 470.[0207[ The ninth inlet body 810 includes an inlet body wall 812. The inlet body wall 812 includes an inlet body wall first end portion 814 (e.g., an inlet portion) and a second end portion 817 (e.g., an outlet portion).

[0208] The inlet body wall first end portion 814 has a first diameter. The first diameter of the inlet body wall first end portion 814 is substantially similar to or the same as the first diameter of the inlet body wall first end portion 314.

[0209] The inlet body wall first end portion 814 is centered on a central axis 425 of the heater assembly 300 (e.g., the central axis 425 extends through a center point of the inlet body wall first end portion 814, etc.). The inlet body wall first end portion 814 defines an inlet body first opening 816.

[0210] The inlet body 810 includes the inlet body wall second end portion 817. The inlet body wall second end portion 817 is the same as the inlet body wall second end portion 317 of the first inlet body 310. The inlet body wall second end portion 817 is centered on the central axis 425. In this way the ninth inlet body 810 receives and provides exhaust in an extending direction of the central axis 425. That is the ninth inlet body 810 has an “axial” directional configuration. An “axial” directional configuration refers to an inlet body that receives exhaust in a first direction and provides exhaust in the first direction. For example, the exhaust flows along the central axis 425 of the heater assembly 300.

[0211] The inlet body 810 may also include an inlet body wall intermediate portion 818 that extends between the inlet body wall first end portion 814 and the inlet body wall second end portion 817. The inlet body wall intermediate portion 818 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 818 isstructured to accommodate the axial configuration of the inlet body 810 and is structured to accommodate an inner body 820 of the inlet body 810.|0212] The inlet body 810 includes the inner body 820 disposed at least partially within the inlet body wall 812. The inner body 820 includes an inner body wall 822. The inner body wall 822 is positioned within and coupled to the inlet body wall 812. For example, the inner body wall 822 is coupled to the inlet body wall intermediate portion 818, between the inlet body wall first end portion 814 and the inlet body wall second end portion 817. The inner body 820 is configured to receive the exhaust gas (e.g., via the inlet body first opening 816).|0213] The inner body wall 822 defines one or more openings 824 therethrough. The one or more openings 824 are directed axially through the inner body wall 822. In an example embodiment, the one or more openings 824 are disposed in a pattern on the inner body wall 822 (e.g., between the center of the inner body wall 822 and the perimeter of the inner body wall 822). The one or more openings 824 allow exhaust to flow therethrough. More specifically, exhaust received by the inner body 820 (e.g., via the inlet body first opening 816) flows through inner body 820 (e.g., into a downstream portion of the inlet body 810) via the one or more openings 824. Advantageously, as the exhaust flows through the one or more openings 824, the exhaust is straightened, such that the turbulent flow in the exhaust gas is substantially reduced. The inner body 820 is structured to straighten a flow of exhaust flowing therethrough by causing the exhaust to flow through the one or more openings 824.

[0214] In some embodiments, the heater assembly 300 includes an inlet endcap 819 disposed at the inlet body 810. More specifically, the inlet endcap 819 is coupled to the inlet body 810 at the inlet body wall first end portion 814. The inlet endcap 819 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 819 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 819 is four inches.[0215| The heater assembly 300 includes the heat shield 470 disposed around the heater body330. The heat shield 470 is disposed around at least a portion of the outlet body 350. The heatshield 470 is disposed around at least a portion of the inlet body 810. The heat shield 470 is configured to thermally isolate, at least partially, an inner volume of the heat shield 470 from a volume outside the heat shield 470.

[0216] In some embodiments, the heat shield 470 includes a heat shield body 478. The heat shield body 478 is disposed around at least a portion of the inlet body 810, around the heater body 330, and around at least a portion of the outlet body 350. In some embodiments, the heat shield body 478 is coupled to at least one of the inlet body 810, the heater body 330, and / or the outlet body 350. In an example embodiment, the heat shield 370 includes a heat shield flange 476. The heat shield flange 476 facilities coupling at least a portion of the heat shield 470, such as the heat shield body 478, to the outlet body 350. For example, the heat shield flange 476 may couple to the second upstream engagement member wall portion 362. In this way the upstream engagement member 354 facilities coupling the outlet body 350 to the heat shield 470.|0217] Advantageously, the inlet body 810 has an axial configuration allowing exhaust to flow through the heater assembly 300 parallel to the central axis 425. Furthermore, because the inlet body wall second end portion 817 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0218] In some embodiments, the heater assembly 300 includes a mounting bracket 600. The mounting bracket 600 is configured to support the one or more electrode wires 382. The mounting bracket 600 is described in greater detail herein with respect to Figures 16, 17, 20, and 21.

[0219] Referring now to Figures 22 and 23, the heater assembly 300 is shown in another configuration. In the configuration shown in Figures 22 and 23, the heater assembly 300 includes a tenth inlet body 840, the heater body 330, the outlet body 350, and a heat shield 470.

[0220] The tenth inlet body 840 includes an inlet body wall 842. The inlet body wall 842 includes an inlet body wall first end portion 844 (e.g., an inlet portion) and a second end portion 847 (e.g., an outlet portion).

[0221] The inlet body wall first end portion 844 has a first diameter. The first diameter of the inlet body wall first end portion 844 is substantially similar to or the same as the first diameter of the inlet body wall first end portion 434. The tenth inlet body 840 differs from the nineth inlet body 810 in that the first diameter of the inlet body wall first end portion 844 is greater than the first diameter of the inlet body wall first end portion 814. The inlet body wall first end portion 844 of the tenth inlet body 840 is sized to accommodate a different (e.g., larger) upstream component compared to the inlet body wall first end portion 814 of the nineth inlet body 810.

[0222] The inlet body wall first end portion 844 is centered on a central axis 425 of the heater assembly 300 (e.g., the central axis 425 extends through a center point of the inlet body wall first end portion 844, etc.). The inlet body wall first end portion 844 defines an inlet body first opening 846.

[0223] The inlet body 840 includes the inlet body wall second end portion 847. The inlet body wall second end portion 847 is the same as the inlet body wall second end portion 317 of the first inlet body 310. The inlet body wall second end portion 847 is centered on the central axis 425. In this way the tenth inlet body 840 receives and provides exhaust in an extending direction of the central axis 425. That is the tenth inlet body 840 has an “axial” directional configuration. An “axial” directional configuration refers to an inlet body that receives exhaust in a first direction and provides exhaust in the first direction. For example, the exhaust flows along the central axis 425 of the heater assembly 300.

[0224] The inlet body 840 may also include an inlet body wall intermediate portion 848 that extends between the inlet body wall first end portion 844 and the inlet body wall second end portion 847. The inlet body wall intermediate portion 848 is substantially similar to the inlet body wall intermediate portion 320 except that the inlet body wall intermediate portion 848 isstructured to accommodate the axial configuration of the inlet body 810 and is structured to accommodate an inner body 850 of the inlet body 840.|0225[ The inlet body 840 includes the inner body 850 disposed at least partially within the inlet body wall 842. The inner body 850 includes an inner body wall 852. The inner body wall 852 is positioned within and coupled to the inlet body wall 842. For example, the inner body wall 852 is coupled to the inlet body wall intermediate portion 848, between the inlet body wall first end portion 844 and the inlet body wall second end portion 847. The inner body 850 is configured to receive the exhaust gas (e.g., via the inlet body first opening 846).|0226] The inner body wall 852 defines one or more openings 854 therethrough. The one or more openings 854 are directed axially through the inner body wall 852. In an example embodiment, the one or more openings 854 are disposed in a pattern on the inner body wall 852 (e.g., between the center of the inner body wall 852 and the perimeter of the inner body wall 852). The one or more openings 854 allow exhaust to flow therethrough. More specifically, exhaust received by the inner body 850 (e.g., via the inlet body first opening 846) flows through inner body 850 (e.g., into a downstream portion of the inlet body 840) via the one or more openings 854. Advantageously, as the exhaust flows through the one or more openings 854, the exhaust is straightened, such that the turbulent flow in the exhaust gas is substantially reduced. The inner body 850 is structured to straighten a flow of exhaust flowing therethrough by causing the exhaust to flow through the one or more openings 854.

[0227] In some embodiments, the heater assembly 300 includes an inlet endcap 849 disposed at the inlet body 840. More specifically, the inlet endcap 849 is coupled to the inlet body 840 at the inlet body wall first end portion 844. The inlet endcap 849 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. The inlet endcap 849 has an outer diameter that is sized to accommodate the upstream component. In an example embodiment, the outer diameter of the inlet endcap 849 is five inches.[0228| The heater assembly 300 includes the heat shield 470 disposed around the heater body 330. The heat shield 470 is disposed around at least a portion of the outlet body 350. The heatshield 470 is disposed around at least a portion of the inlet body 840. The heat shield 470 is configured to thermally isolate, at least partially, an inner volume of the heat shield 470 from a volume outside the heat shield 470.

[0229] In some embodiments, the heat shield 470 includes a heat shield body 478. The heat shield body 478 is disposed around at least a portion of the inlet body 810, around the heater body 330, and around at least a portion of the outlet body 350. In some embodiments, the heat shield body 478 is coupled to at least one of the inlet body 840, the heater body 330, and / or the outlet body 350. In an example embodiment, the heat shield 370 includes a heat shield flange 476. The heat shield flange 476 facilities coupling at least a portion of the heat shield 470, such as the heat shield body 478, to the outlet body 350. For example, the heat shield flange 476 may couple to the second upstream engagement member wall portion 362. In this way the upstream engagement member 354 facilities coupling the outlet body 350 to the heat shield 470.10230] Advantageously, the inlet body 840 has an axial configuration allowing exhaust to flow through the heater assembly 300 parallel to the central axis 425. Furthermore, because the inlet body wall second end portion 847 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0231] In some embodiments, the heater assembly 300 includes a mounting bracket 600. The mounting bracket 600 is configured to support the one or more electrode wires 382. The mounting bracket 600 is described in greater detail herein with respect to Figures 16, 17, 20, and 21.

[0232] Referring now to Figure 24, the heater assembly 300 is shown in another configuration. In the configuration shown in Figure 24, the heater assembly 300 includes a eleventh inlet body 890, the heater body 330, and the outlet body 350. In some embodiments, the heater assembly may also include the heat shield 470, described herein above.

[0233] The eleventh inlet body 890 is substantially similar to the sixth inlet body 490 of Figure 11. For example, the eleventh inlet body 890 includes an inlet body wall 892. The inlet body wall 892 includes an inlet body wall first end portion 894 (e.g., an inlet portion) and a second end portion 897 (e.g., an outlet portion).[02341 The inlet body wall first end portion 894 has a first diameter. The first diameter of the inlet body wall first end portion 894 of the eleventh inlet body 890 is larger than the first diameter of the inlet body wall first end portion 424 of the third inlet body 420 and larger than the inlet body wall first end portion 434 of the fourth inlet body 430.|0235] The inlet body wall first end portion 894 is centered on the center axis 425 of the heater assembly 300 (e.g., the center axis 425 extends through a center point of the inlet body wall first end portion 494, etc.). The inlet body wall first end portion 894 defines an inlet body first opening 896.

[0236] The inlet body 890 includes the inlet body wall second end portion 897. The inlet body wall second end portion 897 is the same as inlet body wall second end portion 497. The inlet body wall second end portion 897 is centered on the central axis 425. In this way the eleventh inlet body 890 receives and provides exhaust in an extending direction of the central axis 425. That is the eleventh inlet body 890 has an axial configuration.

[0237] The inlet body 890 may also include an inlet body wall intermediate portion 898 that extends between the inlet body wall first end portion 894 and the inlet body wall second end portion 897. The inlet body wall intermediate portion 898 is substantially similar to inlet body wall intermediate portion 498.

[0238] In an example embodiment, the inlet body wall first end portion 894 facilitates coupling the heater assembly 300 to an upstream component, such as a conduit or other component of the aftertreatment system 103. In an example embodiment, the first diameter of the inlet body wall first end portion 894 is sized to facilitate coupling the heater assembly 300 to another heater assembly 300. In an example embodiment, the outer diameter of the inlet body wall first end portion 894 is eight inches.

[0239] Advantageously, the inlet body 890 has an axial configuration allowing exhaust to flow through the heater assembly 300 parallel to the central axis 425. Additionally, because the first diameter of the inlet body wall first end portion 894 is sized to facilitate coupling the heater assembly 300 to another heater assembly 300, the inlet body 890 advantageously enables the heater assembly 300 to be provided in series (e.g., when the eleventh inlet body 490 is provided in the downstream heater assembly 300). Furthermore, because the inlet body wall second end portion 827 is the same as inlet body wall second end portion 317, the other components of the heater assembly 300 may remain the same. In this way the heater assembly 300 may be provided in different configurations for use in different applications (e.g., by assembling the heater assembly with an inlet body based on the application).

[0240] Referring back to Figures 1 and 2, in an example embodiment, the aftertreatment system 103 includes one or more heater assemblies 300 and one or more additional components, such as the DOC 126, the DPF 132, the CDV 138, the catalyst member 192, and / or one or more conduits, such as the exhaust conduit system 104 and / or one or more portions thereof. In an example embodiment, the aftertreatment system 103 includes a first heater assembly 300 and a second heater assembly 300.

[0241] The first heater assembly includes a first inlet body (e.g., one of the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890). The first inlet body includes a first inlet body wall (e.g., the inlet body wall 312, the inlet body wall 412, the inlet body wall 422, the inlet body wall 432, the inlet body wall 452, the inlet body wall 492) having a first inlet body wall first end portion (e.g., the first inlet body wall first end portion 314, the first inlet body wall first end portion 414, the first inlet body wall first end portion 424, the first inlet body wall first end portion 434, the first inlet body wall first end portion 454, the first inlet body wall first end portion 494) and a first inlet body wall second end portion (e.g., the inlet body wall second end portion 317, the inlet body wall second end portion 417, the inlet body wall second end portion 427, the inlet body wall second end portion 437, the inletbody wall second end portion 457, the inlet body wall second end portion 497). The first inlet body wall first end portion has a first diameter.|0242] The first heater assembly includes a first heater body 330 having a first heater body wall 332. The first heater assembly includes a first outlet body 350 having a first outlet body wall 352. The first outlet body wall 352 has a first upstream engagement member 354 and a first downstream engagement member 356. The first downstream engagement member 356 has a second diameter. In some embodiment, and as shown in Figure 11, the first diameter of the first inlet body wall first end portion 494 is equal to the second diameter of the downstream engagement member 356. In other embodiments, the first diameter of the first inlet body wall first end portion (e.g., the first inlet body wall first end portion 314, the first inlet body wall first end portion 414, the first inlet body wall first end portion 424, the first inlet body wall first end portion 434, or the first inlet body wall first end portion 454) is different than the second diameter of the downstream engagement member 356.|0243] The aftertreatment system 103 also includes a first component disposed downstream of the first heater assembly 300. The first component may be one of the DOC 126, the DPF 132, the CDV 138, the catalyst member 192, and / or one or more conduits, such as the exhaust conduit system 104 and / or one or more portions thereof. The first component includes an inlet portion having a third diameter. The third diameter is equal to the first diameter. The first component includes an outlet portion having a fourth diameter. The fourth diameter may be equal to the first diameter.[0244| The aftertreatment system 103 also includes a second heater assembly 300. The second heater assembly is disposed downstream of the first heater assembly 300. The second heater assembly includes a second inlet body (e.g., one of the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890). The second inlet body includes a second inlet body wall (e.g., the inlet body wall 312, the inlet body wall 412, the inlet body wall 422, the inlet body wall 432, the inlet body wall 452, the inlet body wall 492) having asecond inlet body wall first end portion (e.g., the first inlet body wall first end portion 314, the first inlet body wall first end portion 414, the first inlet body wall first end portion 424, the first inlet body wall first end portion 434, the first inlet body wall first end portion 454, the first inlet body wall first end portion 494) and a second inlet body wall second end portion (e.g., the inlet body wall second end portion 317, the inlet body wall second end portion 417, the inlet body wall second end portion 427, the inlet body wall second end portion 437, the inlet body wall second end portion 457, the inlet body wall second end portion 497). The second inlet body wall first end portion has a fifth diameter. In some embodiments, the fifth diameter is equal to the first diameter.[0245 [ The second heater assembly includes a second heater body 330 having a second heater body wall 332. The second heater assembly includes a second outlet body 350 having a second outlet body wall 352. The second outlet body wall 352 has a second upstream engagement member 354 and a second downstream engagement member 356. The second downstream engagement member 356 has a sixth. In some embodiment, and as shown in Figure 11, the first diameter of the first inlet body wall first end portion 494 is equal to the sixth diameter of the second downstream engagement member 356.

[0246] In some embodiments, the first component is coupled to the first heater assembly 300, and the second heater assembly 300 is disposed downstream of the first component. In other embodiments, the second heater assembly 300 is coupled to the first heater assembly 300, and the first component is disposed downstream of the second heater assembly.IV. Overview of Example Mounting Brackets[02471 As briefly described above, in some embodiments, the heater assembly 300 includes a mounting bracket 500 (e.g., a first mounting bracket), as shown in Figures 3-10 and / or a mounting bracket 600 (e.g., a second mounting bracket), as shown in Figures 12-24. The mounting bracket 500 is configured to support the one or more electrode wires 382. The mounting bracket 600 is configured to support the one or more electrode wires 382. It should be understood that the mounting bracket 500 may be used interchangeably with the mounting bracket 600. That is, the mounting bracket 500 may be used with any of the embodimentsshown in Figures 12-24 and / or the mounting bracket 600 may be used with any of the embodiments shown in Figures 3-10.|0248] As described above, the heater assembly 300 includes a heater body 330 having a heater body wall 332. The heater body wall 332 at least partially defining a heater body volume 381. The heater 380 is disposed within the heater body volume 381. The heater assembly 300 also includes one or more electrode wires 382 extending through the heater body wall 332.[0249[ As shown in Figure 6, the heater assembly 300 includes a mounting bracket 500 having a mounting bracket body 502 and a retaining bracket body 550. The mounting bracket body 502 is coupled to the heater body wall 332. The retaining bracket body 550 is coupled to the mounting bracket body 502.

[0250] The mounting bracket body 502 has a mounting bracket wall 504. The mounting bracket wall 504 includes a first mounting bracket wall portion 510. The first mounting bracket wall portion 510 defines a first mounting bracket opening 512. In some embodiments, the first mounting bracket wall portion 510 defines one or more additional openings. The first mounting bracket opening 512 is sized to receive a first fastener 514. The first fastener 514 is configured to couple the mounting bracket body 502 to the heater body wall 332.

[0251] The mounting bracket wall 504 includes a first connecting wall portion 516. The first connecting wall portion 516 extends outward from the first mounting bracket wall portion 510. The first connecting wall portion 516 is contiguous with the first mounting bracket wall portion 510. The mounting bracket wall 504 also includes a first raised wall portion 518 extending outward from the first connecting wall portion 516. The first raised wall portion 518 is contiguous with the first connecting wall portion 516. The first raised wall portion 518 is substantially parallel to the first mounting bracket wall portion 510.[0252 [ The mounting bracket wall 504 includes a second mounting bracket wall portion 520. The second mounting bracket wall portion 520 extends outward from the first mounting bracket wall portion 510 at a first angle with respect to an extending direction of the first mountingbracket wall portion 510. The second mounting bracket wall portion 520 is contiguous with the first mounting bracket wall portion 510.|0253] The mounting bracket wall 504 includes a second connecting wall portion 522. The second connecting wall portion 522 extends outward from the second mounting bracket wall portion 520. The second connecting wall portion 522 is contiguous with the second mounting bracket wall portion 520. The mounting bracket wall 504 includes a second raised wall portion 524 extending outward from the second connecting wall portion 522. The second raised wall portion 524 is contiguous with the second connecting wall portion 522. The second raised wall portion 524 is substantially parallel to the second mounting bracket wall portion 520.

[0254] The mounting bracket wall 504 includes a third mounting bracket wall portion 530. The third mounting bracket wall portion 530 extends outward from the second mounting bracket wall portion 520 at a second angle with respect to an extending direction of the second mounting bracket wall portion 520. The third mounting bracket wall portion 530 is contiguous with the second mounting bracket wall portion 520. The third mounting bracket wall portion 530 defines a second mounting bracket opening 532 sized to receive a second fastener 534.

[0255] The mounting bracket wall 504 includes a third connecting wall portion 536 extending outward from the third mounting bracket wall portion 530. The third connecting wall portion 536 is contiguous with the third mounting bracket wall portion 530. The mounting bracket wall 504 includes a third raised wall portion 538 extending outward from the third connecting wall portion 536. The third raised wall portion 538 is contiguous with the third connecting wall portion 536. The third raised wall portion 538 is substantially parallel to the third mounting bracket wall portion 530. The third raised wall portion 538 defines a third mounting bracket opening 539 sized to receive the third fastener 540.|0256[ The retaining bracket body 550 is disposed at the third mounting bracket wall portion 530. The retaining bracket body 550 includes a retaining bracket wall 552. The retaining bracket wall 552 defines a retaining bracket opening (e.g., the first retaining bracket opening) that is sized to receive the second fastener 534. At least a portion of the retaining bracket body550 is spaced away from the mounting bracket body 502 such that a gap 556 is defined therebetween. The one or more electrode wires 382 extend through the gap 556.|0257] The retaining bracket body 550 includes a first retaining bracket wall portion 560 defining the first retaining bracket opening 562 that is sized to receive the second fastener 534.

[0258] The retaining bracket body 550 includes a second retaining bracket wall portion 570. The second retaining bracket wall portion 570 extends outward from the first retaining bracket wall portion 560 and away from the third mounting bracket wall portion 530. The second retaining bracket wall portion 570 defines a second retaining bracket opening 572 sized to receive the third fastener 540.|0259] The retaining bracket body 550 includes a third retaining bracket wall portion 580. The third retaining bracket wall portion 580 extends inward from the second retaining bracket wall portion 570.[O260[ As shown in Figures 16, 17, 20, and 21, the heater assembly 300 includes a mounting bracket 600 having a mounting bracket body 602 and a retaining bracket body 650. The mounting bracket body 602 is coupled to the heater body wall 332. The retaining bracket body 650 is coupled to the mounting bracket body 602.I026.1J As shown in Figures 16 and 20, the mounting bracket body 602 has a mounting bracket wall 604. The mounting bracket wall 604 includes a first mounting bracket wall portion 610. The first mounting bracket wall portion 510 defines a first mounting bracket opening 612. In some embodiments, the first mounting bracket wall portion 610 defines one or more additional openings. The first mounting bracket opening 612 is sized to receive a first fastener 614. The first fastener 614 is configured to couple the mounting bracket body 602 to the heater body wall 332.[02621 The mounting bracket wall 604 includes a first connecting wall portion 616. The first connecting wall portion 616 extends outward from the first mounting bracket wall portion 610. The first connecting wall portion 616 is contiguous with the first mounting bracket wall portion 610. The mounting bracket wall 604 also includes a first raised wall portion 618 extendingoutward from the first connecting wall portion 616. The first raised wall portion 618 is contiguous with the first connecting wall portion 616. The first raised wall portion 618 is substantially parallel to the first mounting bracket wall portion 610. The first raised wall portion 618 defines a opening 619. In some embodiments, the first raised wall portion 618 defines one or more additional openings. The opening 619 may be sized to receive a fastener or another suitable component therethrough.

[0263] The mounting bracket wall 604 includes a second mounting bracket wall portion 620. The second mounting bracket wall portion 620 extends outward from the first mounting bracket wall portion 610 at a first angle with respect to an extending direction of the first mounting bracket wall portion 610. The second mounting bracket wall portion 620 is contiguous with the first mounting bracket wall portion 610.

[0264] The mounting bracket wall 604 includes a second connecting wall portion 622. The second connecting wall portion 622 extends outward from the second mounting bracket wall portion 620. The second connecting wall portion 622 is contiguous with the second mounting bracket wall portion 620. The mounting bracket wall 604 includes a second raised wall portion 624 extending outward from the second connecting wall portion 622. The second raised wall portion 624 is contiguous with the second connecting wall portion 622. The second raised wall portion 624 is substantially parallel to the second mounting bracket wall portion 620.|0265] The mounting bracket wall 604 includes a third mounting bracket wall portion 630. The third mounting bracket wall portion 630 extends outward from the second mounting bracket wall portion 620 at a second angle with respect to an extending direction of the second mounting bracket wall portion 620. The third mounting bracket wall portion 630 is contiguous with the second mounting bracket wall portion 620. The third mounting bracket wall portion 630 defines a second mounting bracket opening 632 sized to receive a second fastener 634. In some embodiments, the third mounting bracket wall portion 630 defines one or more additional openings.[0266| The mounting bracket wall 604 includes a third connecting wall portion 636 extending outward from the third mounting bracket wall portion 630. The third connecting wall portion636 is contiguous with the third mounting bracket wall portion 630. The mounting bracket wall 604 includes a third raised wall portion 638 extending outward from the third connecting wall portion 636. The third raised wall portion 638 is contiguous with the third connecting wall portion 636. The third raised wall portion 638 is substantially parallel to the third mounting bracket wall portion 630. The retaining bracket body 550 is disposed at the third mounting bracket wall portion 530.

[0267] As shown in Figures 17 and 21, the retaining bracket body 650 defines a first retaining bracket opening 652. In some embodiments, the retaining bracket body 650 defines additional first retaining bracket openings 652. The first retaining bracket opening 652 is defined through the retaining bracket body 650 in a radial direction (e.g., relative to the heater body 330). The first retaining bracket opening 652 is sized to receive at least a portion of the one or more electrode wires 382. That is, the one or more electrode wires 382 extend radially through the first retaining bracket opening 652.|0268] The retaining bracket body 650 defines a second retaining bracket opening 654. In some embodiments, the retaining bracket body 650 defines additional second retaining bracket openings 654. The second retaining bracket opening 654 is defined through the retaining bracket body 650 in an axial direction (e.g., relative to the heater body 330). The second retaining bracket opening 654 is sized to receive the second fastener 634. When the second fastener 634 is positioned through the second retaining bracket opening 654 and the second mounting bracket opening 632, the second fastener 634 couples the retaining bracket body 650 to the mounting bracket body 602.V. Overview of Example Manufacturing Process[0269| Figure 25 illustrates a manufacturing process 900 (e.g., method, etc.) for manufacturing an aftertreatment system, such as the aftertreatment system 103. The manufacturing process 900 may be performed by, including but not limited to, the original equipment manufacturer (i.e., when the aftertreatment system 103 is assembled, etc.) or a service technician (e.g., a mechanic, line worker, robot, automated machine, etc.).

[0270] In various embodiments, the manufacturing process 900 begins in block 902 with providing, by the service technician, an inlet body having a first inlet body configuration, such as the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890. In various embodiments, the manufacturing process 900 continues in block 904 with providing, by the service technician, a second inlet body having a second inlet body configuration, such as the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890. The first inlet body configuration is different than the second inlet body configuration. For example, the first inlet body may be any one of the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890, and the second inlet body may be a different one of the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890. Thus, the first and second inlet body configurations may have a different inlet diameter (e.g., the diameter of the inlet body wall first end portion) and / or a different directional configuration (e.g., an angled directional configuration or an axial directional configuration). In an example embodiment, the first and second inlet body configurations have different inlet diameters and the same directional configuration. In another example embodiment, the first and second inlet body configurations have the same inlet diameters and different directional configurations. In yet another example embodiment, the first and second inlet body configurations have different inlet diameters and different directional configurations.[027! ] The manufacturing process 900 continues in block 906 with providing, by the service technician, a plurality of heater bodies 330. As described herein, the heater body 330 includes a heater body wall 332 and a heater 380.

[0272] In some embodiments, the heater bodies 330 include first heater body having a first internal configuration and a second heater body has a second internal configuration, different than the first internal configuration. For example, the first heater body may have a first heater 380 configured to output a first amount of heat energy, and the second heater body may have a second heater configured to output a second amount of heat energy, different than the first amount.

[0273] In other embodiments, the heater bodies 330 include first heater body having a first internal configuration and a second heater body has the first configuration. For example, both the first heater body and the second heater body may have a first heater 380 configured to output a first amount of heat energy.

[0274] As described herein, the heater body wall 332 is the same in any of the heater body configurations. That is each of the heater bodies 330 has the same heater body wall configuration (e.g., a first heater body wall configuration).

[0275] The manufacturing process 900 continues in block 908 with manufacturing, by the service technician, a first aftertreatment system, such as the aftertreatment system 103, by coupling the first inlet body to the inlet of a first heater body of the plurality of heater bodies 330.

[0276] The manufacturing process 900 continues in block 910 with manufacturing, by the service technician, a second aftertreatment system, such as the aftertreatment system 103, by coupling the second inlet body to the inlet of a second heater body of the plurality of heater bodies 330.

[0277] The manufacturing process 900 enables the manufacturing of different aftertreatment systems having the same heater body wall configuration but with different inlet body configurations. Advantageously, by providing different configurations of the inlet body (e.g.,the first inlet body 310, the second inlet body 410, the third inlet body 420, the fourth inlet body 430, the fifth inlet body 450, the sixth inlet body 490, the seventh inlet body 710, the eighth inlet body 740, the ninth inlet body 810, the tenth inlet body 840, or the eleventh inlet body 890), the aftertreatment system 103 may be customized for a particular application. Additionally, in some embodiments, the different aftertreatment systems also have different heater body internal configurations (e.g., different heaters). Advantageously, by providing different configurations of the heater 380, the aftertreatment system 103 may be customized for a particular application.VI. Configuration of Example Embodiments

[0278] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

[0279] As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the appended claims.

[0280] The term “coupled” and the like, as used herein, mean the joining of two components directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components being integrally formed as a single monolithically body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.

[0281] It is important to note that the construction and arrangement of the various systems shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and / or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. When the language “a portion” is used, the item can include a portion and / or the entire item unless specifically stated to the contrary.[0282| Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.Additionally, the use of ranges of values (e.g., W1 to W2, etc.) herein are inclusive of their maximum values and minimum values (e.g., W1 to W2 includes W1 and includes W2, etc.), unless otherwise indicated. Furthermore, a range of values (e.g., W1 to W2, etc.) does not necessarily require the inclusion of intermediate values within the range of values (e g., W1 to W2 can include only W1 and W2, etc.), unless otherwise indicated.

Claims

WHAT IS CLAIMED IS:

1. A heater assembly comprising: an inlet body comprising an inlet body wall having an inlet body wall end portion; a heater body comprising a heater body wall, the heater body wall comprising: a heater body wall central portion, the heater body wall having a first heater body diameter at the heater body wall central portion, and a heater body wall outlet flange comprising: a first outlet flange portion extending axially and radially outward from the heater body wall central portion at a first angle with respect to an extending direction of the heater body wall central portion, and a second outlet flange portion extending axially outward from the first outlet flange portion, substantially parallel to the heater body wall central portion, and contiguous with the first outlet flange portion, the heater body wall having a second heater body diameter at the second outlet flange portion, the second heater body diameter larger than the first heater body diameter; an outlet body comprising an outlet body wall, the outlet body wall comprising: an upstream engagement wall portion comprising: a first upstream engagement member wall portion disposed proximate the heater body wall outlet flange, the outlet body wall having a first outlet body diameter at the first upstream engagement member wall portion, a second upstream engagement member wall portion extending away from the first upstream engagement member wall portion, the outlet body wall having a second outlet body diameter at the second upstream engagement member wall portion, the second outlet body diameter larger than the first outlet body diameter, and a third upstream engagement member wall portion extending away from the second upstream engagement member wall portion, the outlet body wall having a third outlet body diameter at the third upstream engagement member wall portion, the third outlet body diameter larger than the second outlet body diameter; anda heat shield disposed around the heater body and disposed around at least a portion of the outlet body.

2. The heater assembly of claim 1, wherein: the heater body wall further comprises a heater body wall inlet flange comprising: a first inlet flange portion disposed proximate the inlet body wall end portion, the heater body wall having a third diameter at the first inlet flange portion less than the first heater body diameter, and a second inlet flange portion extending axially downstream and radially outward from the first inlet flange portion at a second angle with respect to an extending direction of the first inlet flange portion and contiguous with the first inlet flange portion and the heater body wall central portion.

3. The heater assembly of claim 2, wherein the first inlet flange portion is disposed radially inward from the inlet body wall end portion.

4. The heater assembly of claim 1, wherein: the heater body wall further comprises a port portion comprising: an angled heater body wall portion extending axially and radially outward from the heater body wall central portion at a fourth angle with respect to the extending direction of the heater body wall central portion, and a port wall portion extending axially outward from the angled heater body wall portion and substantially parallel to the heater body wall central portion, the port wall portion defining a port opening.

5. The heater assembly of claim 1, wherein the inlet body further comprises an inner body disposed at least partially within the inlet body wall, the inner body having an inner body wall, the inner body wall defining one or more openings therethrough.

6. The heater assembly of claim 1, wherein: the inlet body wall end portion is an inlet body wall second end portion; the inlet body wall comprises an inlet body wall first end portion; and the inlet body wall first end portion and the inlet body wall second end portion are centered on an axis, such that the inlet body receives and provides an exhaust in an extending direction of the axis.

7. The heater assembly of claim 1, wherein: the inlet body wall end portion is an inlet body wall second end portion; the inlet body wall comprises an inlet body wall first end portion that is centered on a first axis; and the inlet body wall second end portion is centered on a second axis, angled with respect to the first axis, such that the inlet body receives an exhaust in a first direction and provides the exhaust in a second direction different than the first direction.

8. The heater assembly of claim 1, wherein: the inlet body wall end portion is an inlet body wall second end portion; the inlet body wall comprises an inlet body wall first end portion; the heater assembly comprises an inlet endcap coupled to the inlet body at the inlet body wall first end portion, the inlet endcap having an outer diameter; and the outer diameter is at least one of four inches or five inches.

9. An aftertreatment system comprising the heater assembly of claim 1, the aftertreatment system comprising: a first component positioned downstream of the heater assembly; and a second heater assembly positioned downstream of the heater assembly.

10. A method of assembling an aftertreatment system comprising: providing a first inlet body having a first configuration, the first inlet body comprising a first inlet body wall comprising:a first inlet body wall inlet portion having a first diameter, and a first inlet body wall outlet portion having a second diameter; providing a second inlet body having a second configuration, the second inlet body comprising an inlet body wall comprising: a second inlet body wall inlet portion having a third diameter, different than the first diameter, and an inlet body wall outlet portion having the second diameter; providing a plurality of heater bodies, each of the plurality of heater bodies having a first heater body wall configuration; manufacturing a first aftertreatment system by coupling the first inlet body to a first inlet of a first heater body; and manufacturing a second aftertreatment system by coupling the second inlet body to a second inlet of a second heater body of the plurality of heater bodies.

11. The method of claim 10, wherein the first heater body has a first internal configuration, and the second heater body has a second internal configuration, different than the first internal configuration.

12. The method of claim 10, wherein the first heater body has a first internal configuration, and the second heater body has the first internal configuration.

13. A heater assembly for an aftertreatment system component, the heater assembly comprising: a heater body having heater body wall, the heater body wall at least partially defining a heater body volume; a heater disposed in the heater body volume; one or more electrode wires extending through the heater body wall; a mounting bracket body coupled to the heater body wall, the mounting bracket body having a mounting bracket wall, the mounting bracket wall comprising:a first mounting bracket wall portion defining a first mounting bracket opening sized to receive a first fastener, a second mounting bracket wall portion extending outward from the first mounting bracket wall portion at a first angle with respect to an extending direction of the first mounting bracket wall portion and contiguous with the first mounting bracket wall portion, and a third mounting bracket wall portion extending outward from the second mounting bracket wall portion at a second angle with respect to an extending direction of the second mounting bracket wall portion and contiguous with the second mounting bracket wall portion, the third mounting bracket wall portion defining a second mounting bracket opening sized to receive a second fastener; and a retaining bracket body disposed at the third mounting bracket wall portion, the retaining bracket body having a retaining bracket wall, the retaining bracket wall defining a retaining bracket opening sized to receive the second fastener, at least a portion of the retaining bracket body spaced away from the mounting bracket body such that a gap is defined therebetween, wherein the one or more electrode wires extend through the gap.

14. The heater assembly of claim 13, wherein: the retaining bracket body comprises: a first retaining bracket wall portion defining a first retaining bracket opening sized to receive the second fastener, a second retaining bracket wall portion extending outward from the first retaining bracket wall portion and away from the third mounting bracket wall portion, the second retaining bracket wall portion defining a second retaining bracket opening sized to receive a third fastener, and a third retaining bracket wall portion extending inward from the second retaining bracket wall portion.

15. The heater assembly of claim 14, wherein: the mounting bracket wall further comprises:a first connecting wall portion extending outward from the first mounting bracket wall portion and contiguous with the first mounting bracket wall portion, and a first raised wall portion extending outward from the first connecting wall portion and contiguous with the first connecting wall portion, the first raised wall portion substantially parallel to the first mounting bracket wall portion.

16. The heater assembly of claim 15, wherein: the mounting bracket wall further comprises: a second connecting wall portion extending outward from the second mounting bracket wall portion and contiguous with the second mounting bracket wall portion, and a second raised wall portion extending outward from the second connecting wall portion and contiguous with the second connecting wall portion, the second raised wall portion substantially parallel to the second mounting bracket wall portion.

17. The heater assembly of claim 16, wherein: the mounting bracket wall further comprises: a third connecting wall portion extending outward from the third mounting bracket wall portion and contiguous with the third mounting bracket wall portion, and a third raised wall portion extending outward from the third connecting wall portion and contiguous with the third connecting wall portion, the third raised wall portion substantially parallel to the third mounting bracket wall portion and defining a third mounting bracket opening sized to receive the third fastener.

18. An aftertreatment system comprising: a first heater assembly comprising: a first inlet body comprising a first inlet body wall having a first inlet body wall first end portion and a first inlet body wall second end portion, the first inlet body wall first end portion having a first diameter, a first heater body comprising a first heater body wall, andan first outlet body comprising a first outlet body wall having a first upstream engagement member and a first downstream engagement member, the first downstream engagement member having a second diameter, equal to the first diameter; a first component disposed downstream of the first heater assembly, the first component comprising an inlet portion having a third diameter, equal to the first diameter, and an outlet portion having a fourth diameter, equal to the first diameter; and a second heater assembly disposed downstream of the first heater assembly, the second heater assembly comprising: a second inlet body comprising a second inlet body wall having a second inlet body wall first end portion and a second inlet body wall second end portion, the second inlet body wall first end portion having a fifth diameter, equal to the first diameter, a second heater body comprising a second heater body wall, and a second outlet body comprising a second outlet body wall having a second upstream engagement member and a second downstream engagement member, the second downstream engagement member having a sixth diameter, equal to the first diameter.

19. The aftertreatment system of claim 18, wherein: the first component is coupled to the first heater assembly; and the second heater assembly is disposed downstream of the first component.

20. The aftertreatment system of claim 18, wherein: the second heater assembly is coupled to the first heater assembly; and the first component is disposed downstream of the second heater assembly.

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