Exhaust heater electric current adaptors for aftertreatment systems

Abstract

An exhaust heater electric current adaptor includes a first connector and a second connector. The first connector includes a first ring terminal assembly and a first conductor. The first conductor includes a first conductor end electrically coupled to the first ring terminal assembly. The second connector includes a second ring terminal assembly and a second conductor. The second conductor includes a second conductor end electrically coupled to the second ring terminal assembly. The exhaust heater electric current adaptor includes a cover formed from a polymeric material. The cover covers a portion of the first ring terminal assembly, a portion of the first conductor end, a portion of the second ring terminal assembly, and a portion of the second conductor end. In some embodiments, the exhaust heater electric current adaptor includes a third connector.

Description

Atty. Dkt. No.: 106389-9579EXHAUST HEATER ELECTRIC CURRENT ADAPTORS FOR AFTERTREATMENT SYSTEMSCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 689,954, filed on September 3, 2024, the entire disclosure of which is incorporated herein by reference for all purposes.TECHNICAL FIELD

[0002] The present disclosure relates generally to exhaust heater electric current adaptors for aftertreatment systems for use with internal combustion (IC) engines.BACKGROUND

[0003] The exhaust of internal combustion engines, such as diesel engines, includes nitrogen oxide (NOx) compounds. To reduce NOx emissions, a treatment fluid may be dosed into the exhaust by a doser assembly within an aftertreatment system. The treatment fluid facilitates conversion of a portion of the exhaust into non-NOx emissions, such as nitrogen (N2), carbon dioxide (CO2), and water (H2O), thereby reducing NOx emissions. Such an aftertreatment system may include a heater than increases a temperature of the exhaust.SUMMARY

[0004] In one embodiment, an exhaust heater electric current adaptor includes a first connector including a first ring terminal assembly, and a first conductor comprising a first conductor end electrically coupled to the first ring terminal assembly. The exhaust heater electric current adaptor also includes a second connector including a second ring terminal assembly, and a second conductor comprising a second conductor end electrically coupled to the second ring terminal assembly. The exhaust heater electric current adaptor also includes a cover formed from a polymer, the cover covering a portion of the first ring terminal assembly, a portion of the first conductor end, a portion of the second ring terminal assembly, and a portion of the second conductor end.4910-9199-7525 - 1 -Atty. Dkt. No.: 106389-9579

[0005] In some embodiments, the first ring terminal assembly includes a first ring terminal including a first ring base having a first base aperture, and a first lug projecting from the first ring base. The first ring terminal assembly also includes a first screw having a first screw head coupled to the first lug. The second ring terminal assembly includes a second ring terminal including a second ring base having a second base aperture, and a second lug projecting from the second ring base. The second ring terminal assembly includes a second screw having a second screw head coupled to the second lug. In some embodiments, the exhaust heater electric current adaptor further includes a first cover removably coupled to the first connector, the first cover covering a portion of the first screw and extending over the cover and a second cover removably coupled to the second connector, the second cover covering a portion of the second screw and extending over the cover. In some embodiments, the first conductor is centered on a first axis, the first screw is centered on a second axis, parallel to and offset from the first axis, the second conductor is centered on a third axis, and the second screw is centered on a fourth axis, parallel to and offset from the third axis. In some embodiments, the third axis is parallel to and offset from the first axis and the second axis and the fourth axis is parallel to and offset from the first axis and the second axis.

[0006] In some embodiments, the first conductor does not contact the first screw and the second conductor does not contact the second screw. The first conductor further includes a first conductor core formed from a metallic material, a first conductor sheath formed from an alkaline earth metal oxide, and a first seal, the first seal disposed in the first conductor sheath, including a ceramic material and the second connector includes a second conductor core formed from a metallic material, a second conductor sheath formed from an alkaline earth metal oxide, and a second seal, the second seal disposed in the second conductor sheath, including a ceramic material. The cover includes a top surface and a protrusion projecting from the top surface between the first ring terminal assembly and the second ring terminal assembly. The polymer is glass-filled polyether ether ketone (PEEK). The first connector has a first connector diameter, the second connector has a second connector diameter, and in some embodiments, the first connector diameter is equal to the second connector diameter.

[0007] In some embodiments the exhaust heater electric current adaptor further includes a third connector including a third ring terminal assembly and a third conductor including a third4910-9199-7525 nAtty. Dkt. No.: 106389-9579 conductor end electrically coupled to the third ring terminal assembly. The cover is overmolded around a portion of the first ring terminal assembly, a portion of the first conductor end, a portion of the second ring terminal assembly, a portion of the second conductor end, a portion of the third ring terminal assembly, and a portion of the third conductor end. In some embodiments, the first ring terminal assembly includes a first ring terminal including a first ring base having a first base aperture, and a first lug projecting from the first ring base. The first ring terminal assembly also includes a first screw having a first screw head coupled to the first lug. In some embodiments, the second ring terminal assembly includes a second ring terminal including a second ring base having a second base aperture, and a second lug projecting from the second ring base. The second ring terminal assembly also includes a second screw having a second screw head coupled to the second lug. In some embodiments, the third ring terminal assembly includes a third ring terminal including a third ring base having a third base aperture, and a third lug projecting from the third ring base. The third ring terminal assembly also includes a third screw having a third screw head coupled to the third lug.

[0008] In some embodiments, the first conductor is centered on a first axis, the first screw is centered on a second axis, parallel to and offset from the first axis, the second conductor is centered on a third axis, the second screw is centered on a fourth axis, parallel to and offset from the third axis, the third conductor is centered on a fifth axis, and the third screw is centered on a sixth axis, parallel to and offset from the fifth axis. In some embodiments, the fifth axis is parallel to and offset from the first axis, the second axis, the third axis, and the fourth axis and the sixth axis is parallel to and offset from the first axis, the second axis, the third axis, and the fourth axis. The third connector includes a third conductor core formed from a metallic material, a third conductor sheath formed from an alkaline earth metal oxide, and a third seal, the third seal disposed in the third conductor sheath, including a ceramic material. The third connector is disposed between the first connector and the second connector. The first connector has a first connector diameter, the second connector has a second connector diameter, the third connector has a third connector diameter, and, in some embodiments, the first connector diameter greater than the second connector diameter and the third connector diameter. In some embodiments, the first conductor end, the second conductor end, and the third conductor end have a rectangular shape.4910-9199-7525 - 3 -Atty. Dkt. No.: 106389-9579

[0009] In some embodiments, an exhaust aftertreatment system includes the exhaust heater electric current adaptor, an electric heater electrically coupled to the first conductor and the second conductor, and a heat shield including an opening, the heat shield extending around the electric heater, and the first connector and the second connector extend through the opening. The exhaust aftertreatment system also includes a cover support, the cover support coupled to the heat shield and the cover, the cover support extending at an angle between 60 to 85 degrees, inclusive, from the heat shield.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

[0011] FIG. 1 is a block schematic diagram of an example vehicle power system including an exhaust aftertreatment system that includes a heater assembly;

[0012] FIG. 2 is a block schematic diagram of the exhaust aftertreatment system of FIG. 1;

[0013] FIG. 3 is a perspective view of a portion of an example heater assembly;

[0014] FIG. 4 is a perspective view of a portion of the heater assembly of FIG. 3;

[0015] FIG. 5 is a perspective view of another portion of the heater assembly of FIG. 3;

[0016] FIG. 6 is a detailed view of DETAIL A in FIG. 5;

[0017] FIG. 7 is a cross-sectional view of the portion of the heater assembly shown in FIG. 6 taken along plane A-A in FIG. 6;

[0018] FIG. 8 is a perspective view of a portion of the heater assembly of FIG. 3;

[0019] FIG. 9 is an exploded view of a portion of the heater assembly of FIG. 3; 4910-9199-7525Atty. Dkt. No.: 106389-9579

[0020] FIG. 10 is a perspective view of a portion of another example heater assembly;

[0021] FIG. 11 is a perspective view of another portion of the heater assembly of FIG. 10; and

[0022] FIG. 12 is a perspective view of a portion of the heater assembly of FIG. 10.

[0023] Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.DETAILED DESCRIPTION

[0024] Following below are more detailed descriptions of various concepts related to, and implementations of a exhaust heater electric current adaptor 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

[0025] An exhaust aftertreatment system can include a heater to facilitate treatment of exhaust with a treatment fluid. To reduce emissions of the exhaust aftertreatment system, the heater can be an electric heater. However, poor electrical connections of the electric heater can lead to overheating, high resistance, sparking, and can lead to failure of the electric heater. The poor electrical connections can be a result of variability between parts of the electrical connections (e.g., wires, conductors, etc.). A low tolerance for variability between parts of the4910-9199-7525 - 5 -Atty. Dkt. No.: 106389-9579 electrical connections can lead to manufacturing and serviceability difficulty, as well as poor electrical connections.

[0026] Furthermore, the electrical connections of the electric heater are exposed to high heat (e.g., 500 degrees Celsius) due to various components of the exhaust aftertreatment system or vehicle (e.g., an engine). The electrical connections are thus carrying electric currents while also being exposed to the high heat. The electrical connections are also exposed to various road conditions (e.g., debris, water, etc.) which can cause failure.

[0027] Implementations herein are directed towards embodiments of an exhaust heater electric current adaptor (e.g., electrical connector). The exhaust heater electric current adaptor includes a cover which can be made from overmolded polymer. The cover protects conductors carrying a electric current to the electric heater from heat and outside elements (e.g., debris).

[0028] One exhaust heater electric current adaptor includes a first connector and a second connector. The first connector may receive electric current from a power source (e.g., battery) and deliver the electric current to a resistance coil of an electric heater. The electric heater may be proximate or coupled to a catalyst member of an exhaust aftertreatment system. Heating of the catalyst member may facilitate treatment of the exhaust by raising a temperature of the catalyst member to improve an efficiency of a reaction between the exhaust and the treatment fluid. The second connector may then deliver electric current from the resistance coil back to the power source, completing an electrical circuit. Both the first connector and the second connector may include a ring terminal assembly and a conductor where the ring terminal assembly is electrically coupled to an electrical conduit electrically coupled to the battery, and the conductor is electrically coupled to the resistance coil.

[0029] In some implementations, a portion of the ring terminal assembly and the connector are overmolded by a plastic cover. The plastic cover protects the connector and the ring terminal assembly from heat, outside elements, and prevents a loss of electrical connection between the connector and the ring terminal assembly.

[0030] The cover can be supported by a cover support coupled to a heat shield. The electric heater can be disposed in the heat shield. The exhaust heater electric current adaptor can also4910-9199-7525 - 6 -Atty. Dkt. No.: 106389-9579 include a third connector to carry a higher electric current (e.g., 10 kilowatts (kW), etc.) compared to the exhaust heater electric current adaptor with the first and second connector (e.g., 5 kW, etc.).II. Overview of Example Vehicle Power System

[0031] FIG. 1 depicts a vehicle power system 100. The vehicle power system 100 includes a vehicle 102 (e.g., a car, a truck, a hybrid vehicle, etc.). The vehicle 102 includes an engine 104 (e.g., an internal combustion engine, etc.). The engine 104 is configured to (e.g., structured to, able to, etc.) receive a fluid mixture of fuel (e.g., diesel, gasoline, hydrogen, etc.) and air, combust the fluid mixture, and provide exhaust as a result of the combustion of the fluid mixture.

[0032] The vehicle 102 also includes a battery 106 (e.g., an on-vehicle battery, an energy storage device, capacitor, fuel cell, etc.). The battery 106 is configured to provide electrical power to one or more components of the vehicle 102. For example, the battery 106 may provide electrical power to lights, an air conditioning unit, motors, displays, or the like, of the vehicle 102. Additionally, the battery 106 may be utilized for powering the vehicle 102 (e.g., for powering electric driving motors where the vehicle 102 is a hybrid vehicle, etc.). In embodiments in which the engine 104 is a spark-ignition engine, the battery 106 may be electrically or communicatively coupled to the engine 104 and provide electrical power to spark plugs of the engine 104.

[0033] The vehicle 102 also includes an alternator 108 (e.g., a generator, etc.). The alternator 108 is configured to convert mechanical power produced by the engine 104 into electrical power. The alternator 108 may be electrically or communicatively coupled to the battery 106 and configured to provide the electrical power to the battery 106 (i.e., to charge the battery 106, etc.). For example, when the vehicle 102 is moving, rotational energy provided by the engine 104 may be provided to movement members (e.g., wheels, etc.) and the alternator via a serpentine belt drive system.

[0034] The vehicle 102 further includes an exhaust aftertreatment system 110. The exhaust aftertreatment system 110 is disposed downstream of the engine 104. The exhaust4910-9199-7525 - 7 -Atty. Dkt. No.: 106389-9579 aftertreatment system 110 is configured to treat the exhaust produced by the engine 104. As illustrated in FIG. 2, the exhaust aftertreatment system 110 includes an exhaust conduit system 112. The exhaust conduit system 112 is configured to receive the exhaust from the engine 104 via an inlet 114. The exhaust aftertreatment system 110 further includes a particulate filter 116 (e.g., a diesel particulate filter (DPF), etc.).

[0035] The particulate filter 116 is coupled to the exhaust conduit system 112 and configured to remove particulate matter, such as soot, from the exhaust flowing in the exhaust conduit system 112. The particulate filter 116 includes an inlet, where the exhaust is received, and an outlet, where the exhaust exits after having particulate matter substantially filtered from the exhaust and / or converting the particulate matter into CO2. In some embodiments, the particulate filter 116 is omitted from the exhaust aftertreatment system 110.

[0036] The exhaust aftertreatment system 110 further includes a decomposition chamber 118 (e.g., reactor, reactor pipe, conduit, housing, etc.) disposed downstream of the particulate filter 116. The decomposition chamber 118 is configured to receive the exhaust from the particulate filter 116. The exhaust aftertreatment system 110 further includes a treatment fluid delivery system 120 coupled to the decomposition chamber 118. The treatment fluid delivery system 120 is configured to deliver treatment fluid to the decomposition chamber 118. The treatment fluid may be, for example, a reductant (e.g., a urea, a diesel exhaust fluid (DEF), Adblue®, a urea water solution (UWS), an aqueous urea solution (e.g., AUS32, etc.), and / or other similar fluids) or a hydrocarbon fluid (e.g., a fuel, an oil, an additive, etc.). When the reductant is introduced into the exhaust, reduction of emission of undesirable components (e.g., NOx, etc.) in the exhaust may be facilitated. When the hydrocarbon fluid is introduced into the exhaust, the temperature of the exhaust may be increased (e.g., to facilitate regeneration of components of the exhaust aftertreatment system 110, etc.). For example, the exhaust aftertreatment system 110 may include an igniter 122 (e.g., spark plug, etc.) configured to increase the temperature of the exhaust by combusting the hydrocarbon fluid within the exhaust. The decomposition chamber 118 includes an inlet in fluid communication with the particulate filter 116 to receive the exhaust containing NOx emissions and an outlet for the exhaust, NOx emissions, ammonia, and / or the treatment fluid to flow to downstream components of the exhaust aftertreatment system 110.4910-9199-7525 - 8 -Atty. Dkt. No.: 106389-9579

[0037] The treatment fluid delivery system 120 includes a doser assembly 124 (e.g., a dosing module, etc.) configured to dose the treatment fluid into the decomposition chamber 118 (e.g., via an injector). The doser assembly 124 is coupled to (e.g., mounted to, affixed to, fastened to, etc.) the decomposition chamber 118 such that the doser assembly 124 may dose the treatment fluid into the exhaust flowing through the exhaust conduit system 112.

[0038] The doser assembly 124 is fluidly coupled to (e.g., fluidly configured to communicate with, etc.) a treatment fluid source 126. The treatment fluid source 126 may include multiple treatment fluid sources 126. The treatment fluid source 126 may be, for example, a diesel exhaust fluid tank containing Adblue®. A treatment fluid pump 128 (e.g., a supply unit, etc.) is used to pressurize the treatment fluid from the treatment fluid source 126 for delivery to the doser assembly 124. In some embodiments, the treatment fluid pump 128 is pressure-controlled (e.g., controlled to obtain a target pressure, etc.). The treatment fluid pump 128 may include a treatment fluid filter 130. The treatment fluid filter 130 filters (e.g., strains, etc.) the treatment fluid prior to the treatment fluid being provided to internal components (e.g., pistons, vanes, etc.) of the treatment fluid pump 128. For example, the treatment fluid filter 130 may inhibit or prevent the transmission of solids (e.g., solidified treatment fluid, contaminants, etc.) to the internal components of the treatment fluid pump 128. In this way, the treatment fluid filter 130 may facilitate prolonged desirable operation of the treatment fluid pump 128. In some embodiments, the treatment fluid pump 128 is coupled (e.g., fastened, attached, affixed, welded, etc.) to a chassis of the vehicle 102.

[0039] The doser assembly 124 includes at least one injector 132. Each of the injectors 132 is configured to dose the treatment fluid into the exhaust (e.g., within the decomposition chamber 118, etc.) at an injection axis 134. The exhaust aftertreatment system 110 may include a mixer 136 (e.g., a mixing body assembly, a swirl generating device, a vane plate, an inlet plate, a deflector plate, etc.). In some embodiments, at least a portion of the mixer 136 may be located within the decomposition chamber 118. In further embodiments, at least a portion of the mixer 136 may also be located in a conduit of the exhaust conduit system 112 (e.g., a conduit upstream of the decomposition chamber 118, etc.). The mixer 136 is configured to receive the exhaust from the decomposition chamber 118 and the treatment fluid from the injector 132.4910-9199-7525 - 9 -Atty. Dkt. No.: 106389-9579

[0040] The mixer 136 is also configured to facilitate mixing of the exhaust and the treatment fluid. The mixer 136 is configured to facilitate swirling (e.g., tumbling, rotation, etc.) of the exhaust and / or the treatment fluid and mixing (e.g., combination, etc.) of the exhaust and the treatment fluid so as to disperse the treatment fluid within the exhaust downstream of the mixer 136. By dispersing the treatment fluid within the exhaust (e.g., to obtain an increased uniformity index, etc.) using the mixer 136, reduction of emission of undesirable components in the exhaust is enhanced.

[0041] In some embodiments, the injection axis 134 extends into the mixer 136. The injection axis 134 may extend into the mixer 136 at an angle relative to a central axis of the mixer 136. For example, in some embodiments, the injection axis 134 may be substantially coincident with the central axis of the mixer 136. In other embodiments, the injection axis 134 may be substantially perpendicular to the central axis of the mixer 136. In yet other embodiments, the injection axis 134 may be substantially parallel to the central axis of the mixer 136.

[0042] In some embodiments, the injector 132 is not directly coupled to the mixer 136. In these embodiments, the injector 132 and the mixer 136 may each be coupled to a same component (e.g., a housing, a panel, a chamber, a body, etc.). In other embodiments, the injector 132 is directly coupled to the mixer 136. In these embodiments, the injector 132 and the mixer 136 may also each be coupled to the same component. In some embodiments, the injector 132 is not disposed within the mixer 136. In other embodiments, the injector 132 may be at least partially disposed within the mixer 136.

[0043] The treatment fluid delivery system 120 may include an air pump 138. The air pump 138 draws air from an air source 140 (e.g., an air intake, etc.) through an air filter 142 disposed upstream of the air pump 138 and provides the air to the doser assembly 124 via a conduit. In these embodiments, the doser assembly 124 is configured to mix the air and the treatment fluid into an air-treatment fluid mixture and to provide the air-treatment fluid mixture into the decomposition chamber 118. In other embodiments, the treatment fluid delivery system 120 does not include the air pump 138, the air source 140, and / or the air filter 142. In such embodiments, the doser assembly 124 is not configured to mix the treatment fluid with the air.4910-9199-7525 - 10 -Atty. Dkt. No.: 106389-9579

[0044] The exhaust aftertreatment system 110 further includes an exhaust aftertreatment component 144. In some embodiment, the exhaust aftertreatment component 144 includes a catalyst member (e.g., a Selective Catalytic Reduction (SCR) catalyst member, etc.) disposed downstream of the decomposition chamber 118. As a result, the treatment fluid is injected upstream of the catalyst member such that the catalyst member receives a mixture of the treatment fluid and exhaust. Droplets of the treatment fluid undergo processes of evaporation, thermolysis, and hydrolysis to form non-NOx emissions (e.g., gaseous ammonia, etc.) within the exhaust conduit system 112. In other embodiments, the exhaust aftertreatment component 144 includes an oxidation catalyst member (e.g., a diesel oxidation catalyst (DOC), an ammonia oxidation catalyst (AMOx), etc.). In yet other embodiments, the exhaust aftertreatment component 144 includes a particulate filter (e.g., the particulate filter 116, etc.).

[0045] The exhaust aftertreatment component 144 includes an upstream face in fluid communication with the decomposition chamber 118 from which the exhaust and the treatment fluid are received and a downstream face in fluid communication with an outlet 146 of the exhaust conduit system 112. The outlet 146 may release the treated exhaust into an ambient environment or another treatment system.

[0046] The exhaust aftertreatment system 110 may further include an oxidation catalyst member in fluid communication with the exhaust conduit system 112 (e.g., downstream of the exhaust aftertreatment component 144, upstream of the exhaust aftertreatment component 144, upstream of the particulate filter 116, upstream of the decomposition chamber 118, etc.) to oxidize hydrocarbons and carbon monoxide in the exhaust.

[0047] In some embodiments, the particulate filter 116 may be positioned downstream of the decomposition chamber 118. For instance, the particulate filter 116 and the exhaust aftertreatment component 144 may be combined into a single unit.

[0048] The exhaust aftertreatment system 110 may further include a doser mounting bracket 148 (e.g., a coupler, a plate, etc.). The doser mounting bracket 148 couples the doser assembly 124 to a component of the exhaust aftertreatment system 110 (e.g., the decomposition chamber 118, etc.). The doser mounting bracket 148 may be configured as an insulator (e.g., a4910-9199-7525 - 11 -Atty. Dkt. No.: 106389-9579 vibrational insulator, a thermal insulator, etc.). For example, the doser mounting bracket 148 may be configured to mitigate the transfer of heat from the exhaust passing through the exhaust conduit system 112 and / or the decomposition chamber 118 to the doser assembly 124. In this way, the doser assembly 124 is capable of operating more efficiently. The doser mounting bracket 148 may be configured to mitigate transfer of vibrations from components of the exhaust aftertreatment system 110 (e.g., the exhaust conduit system 112, the decomposition chamber 118, etc.) to the doser assembly 124. The doser mounting bracket 148 may be configured to aid in reliable installation of the doser assembly 124, thereby decreasing manufacturing costs associated with the exhaust aftertreatment system 110 and ensuring repeated desirable installation of the doser assembly 124.

[0049] In various embodiments, the doser mounting bracket 148 couples the doser assembly 124 to the decomposition chamber 118. In some embodiments, the doser mounting bracket 148 couples the doser assembly 124 to a conduit of the exhaust conduit system 112. For example, the doser mounting bracket 148 may couple the doser assembly 124 to a conduit of the exhaust conduit system 112 that is upstream of the decomposition chamber 118. In some embodiments, the doser mounting bracket 148 couples the doser assembly 124 to the particulate fdter 116 and / or the exhaust aftertreatment component 144. The location of the doser mounting bracket 148 may be varied depending on the application of the exhaust aftertreatment system 110. For example, in some exhaust aftertreatment systems 110, the doser mounting bracket 148 may be located further upstream than in other exhaust aftertreatment systems 110. Furthermore, some exhaust aftertreatment systems 110 may include multiple doser assemblies 124 and therefore may include multiple doser mounting brackets 148.

[0050] As illustrated in FIGS. 1 and 2, the vehicle power system 100 further includes a controller 150 (e.g., a vehicle power system controller, a treatment fluid delivery system controller, etc.). The controller 150 is electrically or communicatively coupled to the igniter 122. The controller 150 may control the igniter 122 to ignite the treatment fluid in the decomposition chamber 118. For example, where the controller 150 may cause the igniter 122 to provide an electrical arc in a region traversed by the hydrocarbon fluid, and the electrical arc may ignite the hydrocarbon fluid. The controller 150 is electrically or communicatively coupled to the doser assembly 124. The controller 150 may control the doser assembly 124 to4910-9199-7525 1 7Atty. Dkt. No.: 106389-9579 dose the treatment fluid into the decomposition chamber 118. The controller 150 is electrically or communicatively coupled to the treatment fluid pump 128 and / or the air pump 138. The controller 150 may also control operations of the treatment fluid pump 128 and / or the air pump 138. The controller 150 is electrically or communicatively coupled to the engine 104. The controller 150 may also control operations of the engine 104 (e.g., spark plug ignition, fuel injection, etc.). The controller 150 is also electrically or communicatively coupled to the battery 106 and / or the alternator 108. The controller may also control power input and / or power output from and / or to the battery 106 and / or the alternator 108.

[0051] The controller 150 includes a processing circuit 152. The processing circuit 152 includes a processor 154 and a memory 156. The processor 154 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory 156 may include, but is not limited to, electronic, optical, magnetic, or any other storage or transmission device capable of providing the processor 154 with program instructions. This memory 156 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 150 can read instructions. The instructions may include code from any suitable programming language. The memory 156 may include various modules that include instructions which are configured to be implemented by the processor 154.

[0052] The controller 150 may be configured to communicate with a central controller 160 (e.g., engine control unit (ECU), engine control module (ECM), etc.) of the engine 104. In some embodiments, the central controller 160 and the controller 150 are integrated into a single controller.

[0053] In some embodiments, the central controller 160 is communicable with a display device (e.g., a screen, a monitor, a touch screen, a heads up display (HUD), an indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 160. For example, the display device may be configured to change between a static state (e.g., displaying a green light, displaying a “SYSTEM OK” message, etc.) and an alarm state (e.g., displaying a blinking red light, displaying a “SERVICE4910-9199-7525 - 13 -Atty. Dkt. No.: 106389-9579NEEDED” message, etc.) based on a communication from the central controller 160. By changing state, the display device may provide an indication to a user (e.g., an operator, a technician, etc.) of a status (e.g., operation, in need of service, etc.) of the treatment fluid delivery system 120 and / or the vehicle power system 100.

[0054] The vehicle power system 100 further includes a heater assembly 170. The heater assembly 170 is disposed within the exhaust aftertreatment system 110. The heater assembly 170 is electrically or communicatively coupled to the controller 150. The heater assembly 170 includes one or more heaters (e.g., a grid gas heater, a surface heater, a resistance heater, a ceramic heater, a thermoelectric heater, a combustion heater, an electrical heater, etc. The heater assembly 170 may be configured to generate heat via energy (e.g., electrical electric current, etc.) The heater assembly 170 may be coupled to at least one of the battery 106 or an external power source 190 to receive electric current from and return electric current to. The heater assembly 170 may be coupled to the exhaust aftertreatment component 144. The heater assembly 170 may be coupled to the particulate filter 116.

[0055] The heater assembly 170 may be proximate to the exhaust aftertreatment component 144 (e.g., less than 1, 3, 5, etc. times a diameter of the exhaust aftertreatment component 144 away from the exhaust aftertreatment component 144, less than 1, 3, 5, etc. times a diameter of the exhaust aftertreatment component heater 172 away from the exhaust aftertreatment component 144, less than 1, 3, 5, etc. times a diameter of the exhaust conduit system 112 away from the exhaust aftertreatment component 144, etc.). For example, the heater assembly 170 may be disposed upstream, within, around, or downstream of the exhaust aftertreatment component 144.

[0056] The heater assembly 170 is configured to increase temperatures of air, the exhaust, and / or the treatment fluid, which may allow the exhaust aftertreatment component 144 to transition from an ambient temperature to an operating temperature (e.g., a temperature higher than the ambient temperature, etc.) relatively quickly (i.e., at a faster rate than the exhaust aftertreatment component 144 would reach the operating temperature without heating assistance from heater assembly 170). Increasing the temperature of the exhaust facilitates evaporation of the treatment fluid which may improve a reaction between the exhaust and the treatment fluid4910-9199-7525 - 14 -Atty. Dkt. No.: 106389-9579 and mitigate deposit accumulation in the exhaust conduit system 112. Increasing the temperature of the exhaust aftertreatment component 144 may increase the NOx efficiency of the exhaust aftertreatment. Increasing the temperature of the exhaust aftertreatment component 144 may also burn particulates (e.g., soot) within the exhaust aftertreatment component 144 and clean the exhaust aftertreatment component 144.

[0057] As illustrated in FIG. 1, the vehicle power system 100 further includes the external power source 190. The external power source 190 is electrically or communicatively coupled to the controller 150. The external power source 190 is separate from the vehicle 102. For example, the external power source 190 is not mounted to the vehicle 102. Any physical connection between the external power source 190 and the vehicle 102 may be made solely for an electrical or communi cational connection, such that the external power source 190 is still considered separate from the vehicle 102. The external power source 190 may include a fixed electrical receptacle (i.e., powered by an electrical grid, etc.) or an electrical generator.III. Overview of Example Heater Assemblies

[0058] FIGS. 3-12 depict various portions of examples of the heater assembly 170, according to various embodiments. As described above, the heater assembly 170 provides heat to the exhaust aftertreatment component 144 to facilitate treatment of the exhaust and the treatment fluid.

[0059] The heater assembly 170 includes an electric heater 202 (e.g., a resistance heater, a grid gas heater, a surface heater, a ceramic heater, a thermoelectric heater, a combustion heater, an electrical heater, etc.). In some embodiments, the electric heater 202 is an electric heater, and includes a resistance coil 204 as shown in FIG. 5, for example. The resistance coil 204 is composed of a material with electrical resistance (e.g., nichrome) greater than 0.55 ohms and less than 0.9 ohms. For example, the resistance coil 204 is composed of 80% nickel and 20% chromium. The heat generated by the resistance coil 204 is directed towards the exhaust aftertreatment component 144.4910-9199-7525 - 15 -Atty. Dkt. No.: 106389-9579

[0060] The heater assembly 170 includes a heat shield 206. The electric heater 202 is disposed in the heat shield 206. The heat shield 206 is configured to mitigate heat transfer from the electric heater 202 to various components of the exhaust aftertreatment system 110 (e.g., the dosing assembly 124). The heat shield 206 is also configured to direct the heat generated by the resistance coil 204 to the exhaust aftertreatment component 144. In some embodiments, the heat shield 206 is coupled to the exhaust aftertreatment component 144. The heat shield 206 includes an opening 208. In some embodiments, the heat shield 206 includes two or more openings.

[0061] The heater assembly 170 includes an exhaust heater electric current adaptor 210. The exhaust heater electric current adaptor 210 is coupled to the electric heater 202, and extends through the opening 208. The exhaust heater electric current adaptor 210 is configured to deliver electric current and receive electric current from the resistance coil 204 and the battery 106. For example, the electric current begins at the battery 106, travels through the exhaust heater electric current adaptor 210 to the resistance coil 204, and then back through the exhaust heater electric current adaptor 210 to the battery 106.

[0062] The exhaust heater electric current adaptor 210 includes a first connector 302, a second connector 304, and a third connector 306. The first connector 302, the second connector 304, and the third connector 306 are coupled to the electric heater 202 and extend through the opening 208. In some embodiments, the first connector 302, the second connector 304, and the third connector 306 are electrically coupled to the resistance coil 204.

[0063] At least one of the first connector 302, the second connector 304, and the third connector 306 is configured to deliver electric current to the resistance coil 204 from the battery 106. At least one of the first connector 302, the second connector 304 and the third connector 306 is configured to receive electric current from the resistance coil 204 and deliver the electric current to the battery 106. For example, the second connector 304 and the third connector 306 receives electric current from the resistance coil 204 while the first connector 302 delivers electric current to the resistance coil 204. In this case, a first connector diameter of the first connector 302 is greater than a second connector diameter of the second connector 304 and a third connector diameter of the third connector 306. The first connector diameter is in a range of4910-9199-7525 - 16 -Atty. Dkt. No.: 106389-95796 to 12 mm, inclusive. The second connector diameter and the third connector diameter is in a range of 3 to 6 mm, inclusive.

[0064] In some embodiments, the first connector 302, the second connector 304, and the third connector 306 are straight. In some embodiments, the first connector 302, the second connector 304, and the third connector 306 are spaced apart by a distance between 15 mm to 60 mm, inclusive. In some embodiments, the first connector 302 is disposed between the third connector 306 and the second connector 304.

[0065] The first connector 302, the second connector 304, and the third connector 306 are electrically coupled to a first electrical conduit 402, a second electrical conduit 404, and a third electrical conduit 406, respectively. The first electrical conduit 402, the second electrical conduit 404, and the third electrical conduit 406 are electrically coupled to the battery 106. At least one of the first electrical conduit 402, a second electrical conduit 404, and a third electrical conduit 406 is electrically coupled to, for example, the battery 106 to deliver electric current. At least one of the first electrical conduit 402, a second electrical conduit 404, and a third electrical conduit 406 is electrically coupled to the battery 106 to receive electric current from. For example, the second electrical conduit 404 and the third electrical conduit 406 deliver electric current from the battery 106 to the second connector 304 and the third connector 306, respectively. The first electrical conduit 402 receives electric current and delivers the electric current back to the battery 106 from the first connector 302.

[0066] As shown further in FIG. 4, the first connector 302 includes a first ring terminal assembly 502. The first ring terminal assembly 502 is electrically coupled to the first electrical conduit 402. The first ring terminal assembly 502 includes a first ring terminal 503 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The first ring terminal 503 is electrically coupled to the first electrical conduit 402. The first ring terminal 503 includes a first ring base 504 having a first base aperture 506. The first ring base 504 includes a first lug 508 projecting from the first ring base 504. The first ring terminal assembly 502 also includes a first screw 510. At least a portion of the first screw 510 extends through the first base aperture 506. The first screw 510 includes a first screw head 512 in contact with the first lug 508. The first screw head 512 is in contact with both the first lug 5084910-9199-7525 - 17 -Atty. Dkt. No.: 106389-9579 and the first ring base 504. In some embodiments, the first screw 510 is press fit into the first base aperture 506. The first screw 510 is composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. In some embodiments, the metallic material is stainless steel. The first screw 510 is centered on a first axis Al. The first base aperture 506 is also centered on the first axis Al.

[0067] In some embodiments, such as in FIG. 4, the first ring terminal assembly 502 also includes a first flange nut 514 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The first flange nut 514 is coupled to the first screw 510 via threads and is in contact with the first ring base 504. In some embodiments, such as in FIG. 3, the first ring terminal assembly 502 is at least partially covered by a first cover 516 (e.g., housing). The first cover 516 is removably coupled to the first connector 302, and covers at least a portion of the first screw 510. The first cover 516 is in contact with the first flange nut 514 and the first ring base 504. The first cover 516 is composed of a insulation material (e.g., silicone). In some embodiments, such as in FIG. 3, the first cover 516 is also in contact with and at least partially covers the first electrical conduit 402.

[0068] The first connector 302 further includes a first conductor 518. The first conductor 518 is electrically coupled to the resistance coil 204. The first conductor 518 receives electric current from the resistance coil 204 to deliver to the battery 106. For example, the electric current travels from the resistance coil 204 to the first conductor 518, through the first ring terminal assembly 502 and the first electrical conduit 402 to the battery 106. In some embodiments, the first conductor 518 receives electric current from the battery 106 and delivers the electric current to the resistance coil 204.

[0069] The first conductor 518 includes a first conductor end 520 electrically coupled to the first ring terminal assembly 502. In some embodiments, the first conductor end 520 is welded to the first ring terminal assembly 502. In some embodiments, the first conductor end 520 has a rectangular shape, and a first face 522 of the first conductor end 520 is contiguous with and welded to the first lug 508. The first conductor end 520 does not contact the first screw 510, as shown in FIG. 7, for example. The first conductor 518 is centered on a second axis A2. The4910-9199-7525 - 18 -Atty. Dkt. No.: 106389-9579 second axis A2 is parallel to and offset from the first axis Al . In some embodiments, the second axis A2 is co-axial or skewed from the first axis Al.

[0070] As shown in, for example, FIG. 7, the first conductor 518 includes a first conductor core 524. The first conductor core 524 is formed from a metallic material. The electric current travels through the first conductor core 524. In some embodiments, the metallic material is nickel-plated copper. The first conductor end 520 extends from the first conductor core 524, and is formed from the metallic material. In some embodiments, a diameter of the first conductor core 524 is greater than a diameter of the first conductor end 520. The first conductor 518 also includes a first conductor sheath 526 extending around the first conductor core 524. The first conductor sheath 526 protects the first conductor core 524 from heat and outside elements (e.g., debris). The first conductor sheath 526 does not extend around the first conductor end 520. The first conductor sheath 526 is formed from an alkaline earth metal oxide. In some embodiments, the alkaline earth metal oxide is magnesium oxide. The first conductor 518 also includes a first seal 528. The first seal 528 provides additional heat protection for the first conductor core 524 and ensures that the first conductor core 524 remains centered on the second axis A2. The first seal 528 is disposed in the first conductor sheath 526. The first seal 528 includes a ceramic material. In some embodiments, such as in FIG. 7, the first seal 528 is disposed in a portion 530 of the first conductor sheath 526 closer to the first conductor end 520 than the resistance coil 204.

[0071] The second connector 304 includes a second ring terminal assembly 602. The second ring terminal assembly 602 is electrically coupled to the second electrical conduit 404. The second ring terminal assembly 602 includes a second ring terminal 603 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The second ring terminal 603 is electrically coupled to the second electrical conduit 404. The second ring terminal 603 includes a second ring base 604 having a second base aperture 606. The second ring base 604 includes a second lug 608 projecting from the second ring base 604. The second ring terminal assembly 602 also includes a second screw 610. At least a portion of the second screw 610 extends through the second base aperture 606. The second screw 610 includes a second screw head 612 coupled to the second lug 608. The second screw head 612 is in contact with both the second lug 608 and the second ring base 604. In some embodiments, the second 4910-9199-7525 i nAtty. Dkt. No.: 106389-9579 screw 610 is press fit into the second base aperture 606. The second screw 610 is composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. In some embodiments, the metallic material is stainless steel. The second screw 610 is centered on a third axis A3. The third axis A3 is parallel to and offset from the first axis Al and the second axis A2. In some embodiments, the third axis A3 is co-axial or skewed from the first axis Al and the second axis A2. The second base aperture 606 is also centered on the third axis A3.

[0072] In some embodiments, such as in FIG. 4, the second ring terminal assembly 602 also includes a second flange nut 614 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The second flange nut 614 is coupled to the second screw 610 via threads and is in contact with the second ring base 604. In some embodiments, such as in FIG. 3, the second ring terminal assembly 602 is at least partially covered by a second cover 616 (e.g., housing). The second cover 616 is removably coupled to the second connector 304, and covers at least a portion of the second screw 610. The second cover 616 is in contact with the second flange nut 614 and the second ring base 604. The second cover 616 is composed of a insulation material (e.g., silicone). In some embodiments, such as in FIG. 3, the second cover 616 is also in contact with and at least partially covers the second electrical conduit 404.

[0073] The second connector 304 further includes a second conductor 618. The second conductor 618 is electrically coupled to the resistance coil 204. The second conductor 618 receives electric current from the battery 106 to deliver to the resistance coil 204. For example, the electric current travels from the battery 106 to the second electrical conduit 404, the second ring terminal assembly 602, the second conductor 618, and then the resistance coil 204 and then returned through the first connector 302. In some embodiments, the second conductor 618 receives electric current from the resistance coil 204 and delivers electric current to the battery 106.

[0074] The second conductor 618 includes a second conductor end 620 electrically coupled to the second ring terminal assembly 602. In some embodiments, the second conductor end 620 is welded to the second ring terminal assembly 602. In some embodiments, the second conductor end 620 has a rectangular shape, and a second face 622 of the second conductor end4910-9199-7525 - 20 -Atty. Dkt. No.: 106389-9579620 is contiguous with and welded to the second lug 608. The second conductor end 620 does not contact the second screw 610, as shown in FIG. 7, for example. The second conductor 618 is centered on a fourth axis A4. The fourth axis A4 is parallel to and offset from the third axis A3. The fourth axis A4 is parallel to and offset from both the first axis Al and the second axis A2 as well. In some embodiments, the fourth axis A4 is co-axial or skewed from at least one of the first axis Al, the second axis A2, or the third axis A3.

[0075] As shown in, for example, FIG. 7, the second conductor 618 includes a second conductor core 624. The second conductor core 624 is formed from a metallic material. The electric current travels through the second conductor core 624. In some embodiments, the metallic material is nickel-plated copper. The second conductor end 620 extends from the second conductor core 624, and is formed from the metallic material. In some embodiments, a diameter of the second conductor core 624 is greater than a diameter of the second conductor end 620. The second conductor 618 also includes a second conductor sheath 626 extending around the second conductor core 624. The second conductor sheath 626 protects the second conductor core 624 from heat and outside elements (e.g., debris). The second conductor sheath 626 does not extend around the second conductor end 620. The second conductor sheath 626 is formed from an alkaline earth metal oxide. In some embodiments, the alkaline earth metal oxide is magnesium oxide. The second conductor 618 also includes a second seal 628. The second seal 628 provides additional heat protection for the second conductor core 624 and ensures that the second conductor core 624 remains centered on the second axis A2. The second seal 628 is disposed in the second conductor sheath 626. The second seal 628 includes a ceramic material. In some embodiments, such as in FIG. 7, the second seal 628 is disposed in a portion 630 of the second conductor sheath 626 closer to the second conductor end 620 than the resistance coil 204.

[0076] The third connector 306 includes a third ring terminal assembly 702. The third ring terminal assembly 702 is electrically coupled to the third electrical conduit 406. The third ring terminal assembly 702 includes a third ring terminal 703 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The third ring terminal 703 is electrically coupled to the third electrical conduit 406. The third ring terminal assembly 702 includes a third ring base 704 having a third base aperture 706. The third ring base 704 includes 4910-9199-7525 1Atty. Dkt. No.: 106389-9579 a third lug 708 projecting from the third ring base 704. In some embodiments, the third lug 708 projects from a different side from the third ring base 704 compared to the first lug 508 and the second lug 608 as seen in, for example, FIG. 8. The third ring terminal assembly 702 also includes a third screw 710. At least a portion of the third screw 710 extends through the third base aperture 706. The third screw 710 includes a third screw head 712 coupled to the third lug 708. The third screw head 712 is in contact with both the third lug 708 and the third ring base 704. In some embodiments, the third screw 710 is press fit into the third base aperture 706. The third screw 710 is composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. In some embodiments, the metallic material is stainless steel. The third screw 710 is centered on a fifth axis A5. The fifth axis A5 is parallel to and offset from the first axis Al, the third axis A2, the third axis A3, and the fourth axis A4. The third base aperture 706 is also centered on the fifth axis A5. In some embodiments, the fifth axis A5 is co-axial or skewed from at least one of the first axis Al, the second axis A2, the third axis A3, or the fourth axis A4.

[0077] In some embodiments, such as in FIG. 4, the third ring terminal assembly 702 also includes a third flange nut 714 composed of a metallic material. In some embodiments, the metallic material is nickel-plated copper. The third flange nut 714 is coupled to the third screw 710 via threads and is in contact with the third ring base 704. In some embodiments, such as in FIG. 3, the third ring terminal assembly 702 is at least partially covered by a third cover 716 (e.g., housing). The third cover 716 is removably coupled to the third connector 306, and covers at least a portion of the third screw 710. The third cover 716 is in contact with the third flange nut 714 and the third ring base 704. The third cover 716 is composed of a insulation material (e.g., silicone). In some embodiments, such as in FIG. 3, the third cover 716 is also in contact with and at least partially covers the third electrical conduit 406.

[0078] The third connector 306 further includes a third conductor 718. The third conductor 718 is electrically coupled to the resistance coil 204. The third conductor 718 receives electric current from the battery 106 to deliver to the resistance coil 204. For example, the electric current travels from the battery 106 to the third electrical conduit 406, the third ring terminal assembly 702, the third conductor 718, and then the resistance coil 204 and then returned through the first connector 302. In some embodiments, the electric current delivered from the4910-9199-7525 99Atty. Dkt. No.: 106389-9579 battery 106 splits between the second electrical conduit 404 and the third electrical conduit 406. In this case, the second conductor 618 and the third conductor 718 can carry a first electric current and a second electric current, the first electric current and the second electric current being equal. For example, the first electric current is 135 A and the second electric current is 135 A. The first conductor 518 can then carry a third electric current, the third electric current being a summation of the first electric current and the second electric current. For example, the third electric current is 270 A. In some embodiments, the third conductor 718 receives electric current from the resistance coil 204 to deliver to the battery 106.

[0079] The third conductor 718 includes a third conductor end 720 electrically coupled to the third ring terminal assembly 702. In some embodiments, the third conductor end 720 is welded to the third ring terminal assembly 702. In some embodiments, the third conductor end 720 has a rectangular shape, and a third face 722 of the third conductor end 720 is contiguous with and welded to the third lug 708. The third conductor end 720 does not contact the third screw 710, as shown in FIG. 7, for example. The third conductor 718 is centered on a sixth axis A6. The sixth axis A6 is parallel to and offset from the fifth axis A5. The sixth axis A6 is parallel to and offset from the first axis Al, the second axis A2, the third axis A3, and the fourth axis A4 as well. In some embodiments, the sixth axis A6 is co-axial or skewed from at least one of the first axis Al, the second axis A2, the third axis A3, the fourth axis A4, or the fifth axis A5.

[0080] As shown in, for example, FIG. 7, the third conductor 718 includes a third conductor core 724. The third conductor core 724 is formed from a metallic material. The electric current travels through the third conductor core 724. In some embodiments, the metallic material is nickel-plated copper. The third conductor end 720 extends from the third conductor core 724, and is formed from the metallic material. In some embodiments, a diameter of the third conductor core 724 is greater than a diameter of the third conductor end 720. The third conductor 718 also includes a third conductor sheath 726 extending around the third conductor core 724. The third conductor sheath 726 protects the third conductor core 724 from heat and outside elements (e.g., debris). The third conductor sheath 726 does not extend around the third conductor end 720. The third conductor sheath 726 is formed from an alkaline earth metal oxide. In some embodiments, the alkaline earth metal oxide is magnesium oxide. The third4910-9199-7525 - 23 -Atty. Dkt. No.: 106389-9579 conductor 718 also includes a third seal 728. The third seal 728 provides additional heat protection for the third conductor core 724 and ensures that the third conductor core 724 remains centered on the third axis A3. The third seal 728 is disposed in the third conductor sheath 726. The third seal 728 includes a ceramic material. In some embodiments, such as in FIG. 7, the third seal 728 is disposed in a portion 730 of the third conductor sheath 726 closer to the third conductor end 720 than the resistance coil 204.

[0081] The heater assembly 170 further includes a cover 802. The cover 802 is formed from a material, such as an insulating material. The cover 802 is formed from a polymeric material including a polymer. In some embodiments, the polymer is glass-filled polyether ether ketone (PEEK). In some embodiments the polymer is 30% glass-filled PEEK. As seen in FIG. 7, the cover 802 covers a portion 532 of the first ring terminal assembly 502, a portion 632 of the second ring terminal assembly 602, a portion 732 of the third ring terminal assembly 702, a portion 534 of the first conductor 518, a portion 634 of the second conductor 618, and a portion 734 of the third conductor 718. In some embodiments, the cover 802 is overmolded over the portion 532 of the first ring terminal assembly 502, the portion 632 of the second ring terminal assembly 602, the portion 732 of the third ring terminal assembly 702, the portion 534 of the first conductor end 520, the portion 634 of the second conductor end 620, and the portion 734 of the third conductor end 720. In some embodiments, the cover 802 includes a first portion and a second portion. The first portion and the second portion being formed from plastic, and configured to clip together. In some embodiments, the cover 802 includes two or more portions formed from plastic.

[0082] The portion 532 includes the first screw head 512, the first lug 508, and, at least partially, the first ring base 504. The portion 632 includes the second screw head 612, the second lug 608, and, at least partially, the second ring base 604. The portion 732 includes the third screw head 712, the third lug 708, and, at least partially, the third ring base 704. The portion 534 includes the first conductor end 520 and the first seal 528. The portion 634 includes the second conductor end 620 and the second seal 628. The portion 734 includes the third conductor end 720 and the third seal 728.4910-9199-7525 - 24 -Atty. Dkt. No.: 106389-9579

[0083] The cover 802 protects the portion 532 of the first ring terminal assembly 502, the portion 632 of the second ring terminal assembly 602, the portion 732 of the third ring terminal assembly 702, the portion 534 of the first conductor 518, the portion 634 of the second conductor 618, and the portion 734 of the third conductor 718 from heat and outside elements (e.g., debris). The cover 802 secures a connection between the first conductor end 520 and the first ring terminal assembly 502, the second conductor end 620 and the second ring terminal assembly 602, and the third conductor end 720 and the third ring terminal assembly 702. The cover 802 secures a position of the first connector 302, the second connector 304, and the third connector 306. For example, the cover 802 ensures that the first conductor 518 remains centered on the second axis A2. The cover 802 is located above the heat shield 206. For example, the cover is located between 60 to 130 mm above the heat shield 206. The first cover 516, the second cover 616, the third cover 716, the first ring terminal 503, the second ring terminal 603, and the third ring terminal 703 extend over the cover 802. In some embodiments, the first conductor sheath 526, the second conductor sheath 626, and the third conductor sheath 726 are press fit into the cover 802.

[0084] The cover 802 includes a top surface 804. A first protrusion 806 and a second protrusion 808 project from the top surface 804. The first protrusion 806 is disposed between the first ring terminal assembly 502 and the second ring terminal assembly 602. The second protrusion 808 is disposed between the second ring terminal assembly 602 and the third ring terminal assembly 702. The first protrusion 806 and the second protrusion 808 prevent contact between the first ring terminal assembly 502, the second ring terminal assembly 602, and the third ring terminal assembly 702. A height of the first protrusion 806 and the second protrusion 808 is less than a height of the first screw 510, the second screw 610, and the third screw 710.

[0085] In some embodiments, the heater assembly 170 includes a cover support 810 as shown in, for example, FIG. 3. The cover support 810 provides support to the cover 802, and prevents movement of the cover 802 during, for example, vibrations. The cover support 810 is coupled to the heat shield 206 and the cover 802. The cover 802 includes a first aperture 812 and a second aperture 814. The first aperture 812 is located below the first protrusion 806, and the second aperture 814 is located below the second protrusion 808. The first aperture 812 is located between the first conductor 518 and the second conductor 618 while the second aperture 4910-9199-7525 ncAtty. Dkt. No.: 106389-9579814 is located between the second conductor 618 and the third conductor 718. The cover support 810 is coupled to the cover 802 via a first bolt 816 and a second bolt 818 extending through the first aperture 812 and the second aperture 814, respectively. The cover support 810 extends at an angle between 40 to 105 degrees, inclusive, from the heat shield 206. For example, the cover support 810 extends at an angle between 60 to 85 degrees, inclusive, from the heat shield 206. In some embodiments, the heater assembly 170 does not include the cover support 810.

[0086] In some embodiments, a heat deflector is coupled to at least one of the first connector 302, the second connector 304, and the third connector 306. The heat deflector is located between the cover 802 and the electric heater 202.

[0087] In some embodiments, the heater assembly 170 does not include the third connector 306 as seen in FIGS. 10-12. The second connector 304 receives electric current from the battery 106 while the first connector 302 delivers electric current to the battery 106. In this case, the first connector diameter and the second connector diameter are equal. The cover 802 covers the portion 532, the portion 632, the portion 534, and the portion 634. The first connector 302 and the second connector 304 are spaced apart by a distance between 60 mm to 120 mm, inclusive. Also, in this case, the cover 802 does not include the second protrusion 808. The first protrusion 806 projects from the top surface 804 and is disposed between the first ring terminal assembly 502 and the second ring terminal assembly 602. The heater assembly 170 not including the third connector 306 produces less heat than the heater assembly 170 including the third connector 306.IV. Configuration of Example Embodiments

[0088] 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 or4910-9199-7525 - 26 -Atty. Dkt. No.: 106389-9579 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.

[0089] 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.

[0090] 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 unitary body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.

[0091] 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.4910-9199-7525 - 27 -Atty. Dkt. No.: 106389-9579

[0092] 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.

[0093] 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.4910-9199-7525 - 28 -

Claims

Atty. Dkt. No.: 106389-9579WHAT IS CLAIMED IS:

1. An exhaust heater electric current adaptor comprising: a first connector comprising: a first ring terminal assembly, and a first conductor comprising a first conductor end electrically coupled to the first ring terminal assembly; a second connector comprising: a second ring terminal assembly, and a second conductor comprising a second conductor end electrically coupled to the second ring terminal assembly; and a cover formed from a polymeric material, the cover covering a portion of the first ring terminal assembly, a portion of the first conductor end, a portion of the second ring terminal assembly, and a portion of the second conductor end.

2. The exhaust heater electric current adaptor of claim 1, wherein: the first ring terminal assembly comprises: a first ring terminal comprising: a first ring base having a first base aperture, and a first lug projecting from the first ring base, and a first screw having a first screw head coupled to the first lug; and the second ring terminal assembly comprises: a second ring terminal comprising: a second ring base having a second base aperture, and a second lug projecting from the second ring base, and a second screw having a second screw head coupled to the second lug.

3. The exhaust heater electric current adaptor of claim 2, further comprising: a first cover removably coupled to the first connector, the first cover covering a portion of the first screw and extending over the cover; and a second cover removably coupled to the second connector, the second cover covering a portion of the second screw and extending over the cover.4910-9199-7525 29Atty. Dkt. No.: 106389-95794. The exhaust heater electric current adaptor of claim 2, wherein: the first conductor is centered on a first axis; the first screw is centered on a second axis parallel to and offset from the first axis; the second conductor is centered on a third axis; and the second screw is centered on a fourth axis parallel to and offset from the third axis.

5. The exhaust heater electric current adaptor of claim 4, wherein: the third axis is parallel to and offset from the first axis and the second axis; and the fourth axis is parallel to and offset from the first axis and the second axis.

6. The exhaust heater electric current adaptor of claim 2, wherein: the first conductor does not contact the first screw; and the second conductor does not contact the second screw.

7. The exhaust heater electric current adaptor of claim 1, wherein: the first conductor comprises: a first conductor core formed from a metallic material, a first conductor sheath formed from an alkaline earth metal oxide, and a first seal disposed in the first conductor sheath, comprising a ceramic material; and the second connector comprises: a second conductor core formed from a metallic material, a second conductor sheath formed from an alkaline earth metal oxide, and a second seal disposed in the second conductor sheath, comprising a ceramic material.

8. The exhaust heater electric current adaptor of claim 1, wherein: the cover comprises: a top surface, and4910-9199-7525 30Atty. Dkt. No.: 106389-9579 a protrusion projecting from the top surface between the first ring terminal assembly and the second ring terminal assembly.

9. The exhaust heater electric current adaptor of claim 1, wherein: the polymeric material is glass-filled polyether ether ketone (PEEK).

10. The exhaust heater electric current adaptor of claim 1, wherein: the first connector has a first connector diameter; the second connector has a second connector diameter; and the first connector diameter is equal to the second connector diameter.

11. The exhaust heater electric current adaptor of claim 1, further comprising: a third connector comprising: a third ring terminal assembly; and a third conductor comprising a third conductor end electrically coupled to the third ring terminal assembly; wherein the cover is overmolded around a portion of the first ring terminal assembly, a portion of the first conductor end, a portion of the second ring terminal assembly, a portion of the second conductor end, a portion of the third ring terminal assembly, and a portion of the third conductor end.

12. The exhaust heater electric current adaptor of claim 11, wherein: the first ring terminal assembly comprises: a first ring terminal comprising: a first ring base having a first base aperture, and a first lug projecting from the first ring base, and a first screw having a first screw head coupled to the first lug; the second ring terminal assembly comprises: a second ring terminal comprising: a second ring base having a second base aperture, and a second lug projecting from the second ring base, and4910-9199-7525 31Atty. Dkt. No.: 106389-9579 a second screw having a second screw head coupled to the second lug; and the third ring terminal assembly comprises: a third ring terminal comprising: a third ring base having a third base aperture, and a third lug projecting from the third ring base, and a third screw having a third screw head coupled to the third lug.

13. The exhaust heater electric current adaptor of claim 12, wherein: the first conductor is centered on a first axis; the first screw is centered on a second axis parallel to and offset from the first axis; the second conductor is centered on a third axis; the second screw is centered on a fourth axis parallel to and offset from the third axis; the third conductor is centered on a fifth axis; and the third screw is centered on a sixth axis parallel to and offset from the fifth axis.

14. The exhaust heater electric current adaptor of claim 13, wherein: the fifth axis is parallel to and offset from the first axis, the second axis, the third axis, and the fourth axis; and the sixth axis is parallel to and offset from the first axis, the second axis, the third axis, and the fourth axis.

15. The exhaust heater electric current adaptor of claim 11, wherein: the third connector comprises: a third conductor core formed from a metallic material, a third conductor sheath formed from an alkaline earth metal oxide, and a third seal, the third seal disposed in the third conductor sheath, comprising a ceramic material.

16. The exhaust heater electric current adaptor of claim 11, wherein: the third connector is disposed between the first connector and the second connector.4910-9199-7525 32Atty. Dkt. No.: 106389-957917. The exhaust heater electric current adaptor of claim 16, wherein: the first connector has a first connector diameter; the second connector has a second connector diameter; the third connector has a third connector diameter; and the first connector diameter greater than the second connector diameter and the third connector diameter.

18. The exhaust heater electric current adaptor of claim 11, wherein: the first conductor end, the second conductor end, and the third conductor end have a rectangular shape.

19. An exhaust aftertreatment system comprising: the exhaust heater electric current adaptor of claim 1; an electric heater electrically coupled to the first conductor and the second conductor; and a heat shield comprising an opening, the heat shield extending around the electric heater; wherein the first connector and the second connector extend through the opening.

20. The exhaust aftertreatment system of claim 19, further comprising: a cover support, the cover support coupled to the heat shield and the cover, the cover support extending from the heat shield at an angle between 60 to 85 degrees, inclusive.4910-9199-7525 33

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