Exhaust heater assemblies for aftertreatment systems

Abstract

An exhaust heater assembly includes a housing including an outer surface and an inner peripheral surface, a heater removably coupled to the housing, a plurality of mounting assemblies coupling the heater to the inner peripheral surface, and an exhaust heater current adaptor removably coupled to the outer surface and the heater, the exhaust heater current adaptor configured to facilitate provision of electrical power to the heater. The exhaust heater current adaptor can include a first cable including a first end and a second end, the first cable centered on a first axis, the first end electrically coupled to the heater, a first connector removably coupled to and extending around the second end, and a first cable gland removably coupled to the first cable and including an aperture, the first cable extending through the aperture.

Description

Atty. Dkt. No.: 106389-9658EXHAUST HEATER ASSEMBLIES FOR AFTERTREATMENT SYSTEMS CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to Indian Provisional Patent Application No.202441103542, filed on December 27, 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 assemblies 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. The heater may be used to facilitate desirable decomposition of the treatment fluid. Additionally, the heater may be used to facilitate regeneration of a component of the aftertreatment system.SUMMARY

[0004] At least one aspect of the present disclosure is directed to an exhaust heater assembly. The exhaust heater assembly can include a housing including an outer surface and an inner peripheral surface. The exhaust heater assembly can include a heater removably coupled to the housing. The exhaust heater assembly can include a plurality of mounting assemblies coupling the heater to the inner peripheral surface. The exhaust heater assembly can include an exhaust heater current adaptor removably coupled to the outer surface and the heater, the exhaust heater current adaptor configured to facilitate provision of electrical power to the heater, the exhaust heater current adaptor including a first cable including a first end and a second end opposite the first end, the first end electrically coupled to the heater, a first 4909-6784-4474 - 1 -Atty. Dkt. No.: 106389-9658connector removably coupled to and extending around the second end, and a first cable gland removably coupled to the first cable and including an aperture, the first cable extending through the aperture.

[0005] In some implementations, the first cable is centered on a first axis. The exhaust heater current adaptor can further include a second cable including a first end and a second end opposite the first end, the second cable centered on a second axis parallel to and offset from the first axis, the first end electrically coupled to the heater. The exhaust heater current adaptor can include a second connector removably coupled to and extending around the second end. The exhaust heater current adaptor can include a second cable gland removably coupled to the second cable and including an aperture, the second cable extending through the aperture.

[0006] In some implementations, the exhaust heater current adaptor includes a first electrical conduit removably coupled with a battery and the first cable via the first connector, the first electrical conduit to provide and receive electrical current from the heater via the first cable and a second electrical conduit removably coupled with the battery and the second cable via the second connector, the second electrical conduit to provide and receive electrical current from the heater via the second cable. The housing can include an opening extending from the inner peripheral surface to the outer surface, the first cable gland and the second cable gland extending through the opening.

[0007] In some implementations, the inner peripheral surface extends around and is centered on a center axis, the plurality of mounting assemblies include a first mounting assembly, a second mounting assembly, and a third mounting assembly, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the first mounting assembly and a line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive, and an angle between a line extending from the center axis through the third mounting assembly and the line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive.4909-6784-4474 - 2 -Atty. Dkt. No.: 106389-9658

[0008] In some implementations, the exhaust heater assembly includes a fourth mounting assembly coupled to the inner peripheral surface, where, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the fourth mounting assembly and the line extending from the center axis through the third mounting assembly is in a range of 70 to 140 degrees, inclusive. In some implementations, the housing includes a housing aperture extending through the inner peripheral surface and each of the plurality of mounting assemblies includes a weld nut disposed in the housing aperture and coupled to the housing, the weld nut including a weld nut aperture, a bearing coupled to the heater and defining a cavity, and a screw including a first portion including a threaded portion that is threadedly coupled to the weld nut aperture, and a second portion contiguous with the first portion, the second portion having a conical shape and contacting the bearing in the cavity.

[0009] In some implementations, the housing includes a housing aperture extending through the inner peripheral surface and each of the plurality of mounting assemblies includes a weld nut disposed in the housing aperture and coupled to the housing, the weld nut comprising a weld nut aperture and a screw including a head located outside the weld nut and in contact with the housing, a shaft contiguous with the head and including a threaded portion that is threadedly coupled to the weld nut aperture, and a ball coupled to the shaft and in contact with the heater such that the weld nut is separated from the heater.

[0010] In some implementations, the housing includes an adaptor including: a first wall coupled to and extending from the inner peripheral surface, a first gasket in contact with the first wall, and a first flange portion in contact with the first gasket and extending to the heater configured to compress the first gasket towards the first wall. The exhaust heater assembly can further include a current adaptor support coupled to the outer surface and removably coupled to the exhaust heater current adaptor.

[0011] Another aspect of the present disclosure is directed to an exhaust heater assembly. The exhaust heater assembly can include a housing including an outer surface and an inner peripheral surface, a heater removably coupled to the housing, a plurality of mounting assemblies coupling the heater to the inner peripheral surface, and an exhaust heater current adaptor removably coupled to the outer surface and the heater, the exhaust heater current 4909-6784-4474 - 3 -Atty. Dkt. No.: 106389-9658adaptor configured to facilitate provision of electrical power to the heater, including a plate including a first side and a second side, the second side opposite to the first side, the first side including a first conductor electrically coupled to the heater, and a first cable coupled to the second side including a first end, the first end extending through the plate and electrically coupled to the first conductor.

[0012] In some implementations, the first cable is centered on a first axis, the first side includes a second conductor not in contact with the first conductor, the second conductor electrically coupled to the heater, and the exhaust heater current adaptor further includes a second cable coupled to the second side including a first end and centered on a second axis, the second axis parallel to and offset from the first axis, the first end extending through the plate and electrically coupled to the second conductor. In some implementations, the first conductor can include a first connection point and a second connection point, the second conductor can include a third connection point and a fourth connection point, and the heater can include at least a first wire, a second wire, a third wire, and a fourth wire extending from the heater and electrically coupled to the plate, the first wire electrically coupled at the first connection point, the second wire electrically coupled at the third connection point, the third wire electrically coupled at the second connection point, and the fourth wire electrically coupled at the fourth connection point.

[0013] In some implementations, the first conductor has a length less than a length of the second conductor. The exhaust heater assembly can include a cable box coupled to the second side of the plate, the cable box including a first aperture and a second aperture, the first cable extending through the first aperture and the second cable extending through the second aperture. A length of the first cable can be greater than a length of the second cable. In some implementations, the housing can include a housing aperture extending through the inner peripheral surface and each of the plurality of mounting assemblies can include a weld nut disposed in the housing aperture and coupled to the housing, the weld nut including a weld nut aperture, a bearing coupled to the heater and defining a cavity, and a screw including a first portion including a threaded portion that is threadedly coupled to the weld nut aperture, and a second portion contiguous with the first portion, the second portion having a conical shape and contacting the bearing in the cavity.4909-6784-4474 - 4 -Atty. Dkt. No.: 106389-9658

[0014] In some implementations, the inner peripheral surface extends around and is centered on a center axis, the plurality of mounting assemblies includes a first mounting assembly, a second mounting assembly, and a third mounting assembly, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the first mounting assembly and a line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive, and an angle between a line extending from the center axis through the third mounting assembly and the line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive.

[0015] In some implementations, the exhaust heater assembly includes a fourth mounting assembly coupled to the inner peripheral surface, where, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the fourth mounting assembly and the line extending from the center axis through the third mounting assembly is in a range of 70 to 140 degrees, inclusive. The exhaust heater assembly can include a clamp removably coupled to the housing and the plate.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 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.

[0017] FIG. 1 is a block schematic diagram of an exhaust aftertreatment system;

[0018] FIG. 2 is a perspective view of a portion of an example exhaust aftertreatment system including an example exhaust heater assembly;

[0019] FIG. 3 is a front view of the portion of the exhaust aftertreatment system of FIG. 2;4909-6784-4474 - 5 -Atty. Dkt. No.: 106389-9658

[0020] FIG. 4 is a cross-sectional view of the portion of the exhaust aftertreatment system of FIG. 3 taken along plane A- A in FIG. 3;

[0021] FIG. 5 is a detailed view of DETAIL A shown in FIG. 4;

[0022] FIG. 6 is a perspective view of a portion of the exhaust aftertreatment system of FIG. 2;

[0023] FIG. 7 is a cross-sectional view of the portion of the exhaust aftertreatment system of FIG. 6 taken along plane B-B in FIG. 6;

[0024] FIG. 8 is a cross-sectional view of a portion of another example exhaust aftertreatment system including another example exhaust heater assembly;

[0025] FIG. 9 is a detailed view of DETAIL B shown in FIG. 8;

[0026] FIG. 10 is another cross-sectional view of the portion of the exhaust aftertreatment system of FIG. 8 taken along plane C-C in FIG. 8;

[0027] FIG. 11 is a detailed view of DETAIL C shown in FIG. 10;

[0028] FIG. 12 is a perspective view of a portion of another example exhaust aftertreatment system including an example exhaust heater assembly;

[0029] FIG. 13 is a front view of the portion of the exhaust aftertreatment system of FIG.12;

[0030] FIG. 14 is a perspective view of a portion of the exhaust aftertreatment system of FIG. 12;

[0031] FIG. 15 is a cross-sectional view of a portion of the exhaust aftertreatment system of FIG. 14 taken along plane D-D in FIG. 13;

[0032] FIG. 16 is a detailed view of DETAIL D shown in FIG. 15;4909-6784-4474 - 6 -Atty. Dkt. No.: 106389-9658

[0033] FIG. 17 is a perspective view of a portion of the exhaust aftertreatment system of FIG. 12; and

[0034] FIG. 18 is a perspective view of a portion of the exhaust aftertreatment system of FIG. 12.

[0035] 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

[0036] Following below are more detailed descriptions of various concepts related to, and implementations of exhaust heater assemblies 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

[0037] An exhaust aftertreatment system can include a heater to facilitate treatment of exhaust with a treatment fluid. To address failure and performance issues in the heater, the entire exhaust heater assembly typically must be replaced. Replacing the exhaust heater assembly can have high costs and is often mechanically difficult, and therefore time consuming and expensive, to accomplish.4909-6784-4474 - 7 -Atty. Dkt. No.: 106389-9658

[0038] Implementations herein are directed towards embodiments of an exhaust heater assembly with a removable heater. By facilitating replacement and servicing of the heater, high costs typically incurred when the exhaust heater assembly is replaced can be avoided.

[0039] The exhaust heater assembly includes a housing, a heater, a plurality of mounting assemblies, and an exhaust heater current adaptor. The heater is removably coupled to the housing via the plurality of mounting assemblies. Each of the plurality of mounting assemblies are located around an inner periphery of the housing to couple the heater to the housing. The exhaust heater current adaptor is at least partially electrically coupled to the heater. For example, a portion of the exhaust heater current adaptor is removably coupled to the heater to allow for removable coupling of the heater to the housing. The heater can thus be replaced and / or serviced, avoiding high costs associated with replacing the entire exhaust heater assembly.IT. Overview of Example Vehicle Power System

[0040] FIG. 1 depicts an aftertreatment system 100 that is configured to treat an exhaust released by an internal combustion engine. The aftertreatment system 100 includes an exhaust conduit system 104 configured to receive the exhaust from the internal combustion engine. The aftertreatment system 100 further includes a particulate filter 106 (e.g., a diesel particulate filter (DPF), etc.) coupled to the exhaust conduit system 104 and configured to (e.g., structured to, able to, etc.) remove particulate matter, such as soot, from the exhaust flowing in the exhaust conduit system 104. The particulate filter 106 includes a particular filter 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 carbon dioxide. In some implementations, the particulate filter 106 may be omitted.

[0041] The aftertreatment system 100 further includes a decomposition chamber 108 (e.g., reactor, reactor pipe, conduit, mixer, etc.) disposed downstream of the particulate filter 106. The decomposition chamber 108 is configured to receive the exhaust from the particulate filter 106. The aftertreatment system 100 further includes a treatment fluid delivery system 102 coupled to the decomposition chamber 108. The treatment fluid delivery system 102 is configured to4909-6784-4474 - 8 -Atty. Dkt. No.: 106389-9658deliver treatment fluid to the decomposition chamber 108. The treatment fluid may be, for example, a reductant (e.g., urea, 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., fuel, oil, 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 aftertreatment system 100, etc.). For example, the aftertreatment system 100 may include a spark plug 109 (e.g., igniter, etc.) configured to increase the temperature of the exhaust by combusting the hydrocarbon fluid within the exhaust. In various embodiments, the aftertreatment system 100 does not include the spark plug 109 as a temperature of the exhaust can be enough to burn the hydrocarbon fluid at a high temperature. The decomposition chamber 108 includes an inlet that is in fluid communication with the particulate filter 106 to receive the exhaust containing NOx emissions and an outlet for the exhaust, NOXemissions, ammonia, and / or the treatment fluid to flow to downstream components of the aftertreatment system 100.

[0042] The treatment fluid delivery system 102 includes a dosing unit 112 (e.g., dosing module, doser assembly, injector, etc.) configured to dose the treatment fluid into the decomposition chamber 108 (e.g., via an injector). The dosing unit 112 is mounted to the decomposition chamber 108 such that the dosing unit 112 may dose the treatment fluid into the exhaust flowing through the exhaust conduit system 104.

[0043] The dosing unit 112 is fluidically coupled to (e.g., coupled in a fluid-conducting manner, etc.) a treatment fluid source 114. The treatment fluid source 114 may include multiple treatment fluid sources 114. The treatment fluid source 114 may be, for example, a diesel exhaust fluid tank containing Adblue®. A treatment supply unit 116 (e.g., fluid pump, etc.) is used to pressurize and deliver the treatment fluid from the treatment fluid source 114 for delivery to the dosing unit 112. In some embodiments, the treatment supply unit 116 is pressure-controlled (e.g., controlled to obtain a target pressure, etc.). The treatment supply unit 116 may include a filter 118 (e.g., treatment fluid filter). The filter 118 filters (e.g., strains, etc.) the treatment fluid prior to the treatment fluid being provided to internal components (e.g., diaphragms, pistons, vanes, etc.) of the treatment supply unit 116. For example, the filter 118 4909-6784-4474 OAtty. Dkt. No.: 106389-9658may inhibit or prevent the transmission of solids (e.g., solidified treatment fluid, contaminants, etc.) to the internal components of the treatment supply unit 116. In this way, the filter 118 may facilitate prolonged desirable operation of the treatment supply unit 116. In some embodiments, the treatment supply unit 116 is coupled (e.g., fastened, attached, affixed, etc.) to a chassis of a vehicle associated with the aftertreatment system 100.

[0044] The dosing unit 112 includes at least one injector 120. Each injector 120 is configured to dose the treatment fluid into the exhaust (e.g., within the decomposition chamber 108, etc.) at an injection axis 119. The aftertreatment system 100 may include a mixer 121 (e.g., a mixing body assembly, a swirl generating device, a vane plate, inlet plate, deflector plate, etc.). In some embodiments, at least a portion of the mixer 121 may be located within the decomposition chamber 108. In further embodiments, at least a portion of the mixer 121 may also be located in a conduit of the exhaust conduit system 104 (e.g., a conduit upstream of the decomposition chamber 108, etc.). The mixer 121 is configured to receive exhaust from the decomposition chamber 108 and the treatment fluid from the injector 120. The mixer 121 is also configured to facilitate mixing of the exhaust and the treatment fluid. The mixer 121 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 121. By dispersing the treatment fluid within the exhaust (e.g., to obtain an increased uniformity index, etc.) using the mixer 121, reduction of emission of undesirable components in the exhaust is enhanced.

[0045] In some embodiments, the injection axis 119 extends into the mixer 121. The injection axis 119 may extend into the mixer 121 at an angle relative to a central axis of the mixer 121. For example, in some embodiments, the injection axis 119 may be substantially coincident with a central axis of the mixer 121. In other embodiments, the injection axis 119 may be substantially perpendicular to the central axis of the mixer 121. In yet other embodiment, the injection axis 119 may be substantially parallel to the central axis of the mixer 121.

[0046] In some embodiments, the injector 120 is not directly coupled to the mixer 121. In these embodiments, the injector 120 and the mixer 121 may each be coupled to a same4909-6784-4474 - 10 -Atty. Dkt. No.: 106389-9658component (e.g., housing, panel, chamber, body, etc.). In other embodiments, the injector 120 is directly coupled to the mixer 121. In these embodiments, the injector 120 and the mixer 121 may also each be coupled to the same component. In some embodiments, the injector 120 is not disposed within the mixer 121. In other embodiments, the injector 120 may be at least partially disposed within the mixer 121.

[0047] In some embodiments, the treatment fluid delivery system 102 also includes an air pump 122. In these embodiments, the air pump 122 draws air from an air source 124 (e.g., air intake, etc.) and through an air filter 126 disposed upstream of the air pump 122. Additionally, the air pump 122 provides the air to the dosing unit 112 via a conduit. In these embodiments, the dosing unit 112 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 108. In other embodiments, the treatment fluid delivery system 102 does not include the air pump 122, the air source 124, and / or the air filter 126. In such embodiments, the dosing unit 112 is not configured to mix the treatment fluid with the air.

[0048] The spark plug 109, the dosing unit 112, and the treatment supply unit 116 are also electrically or communicatively coupled to a treatment fluid delivery system controller 128. The treatment fluid delivery system controller 128 may control the spark plug 109 to ignite the treatment fluid in the decomposition chamber 108. The treatment fluid delivery system controller 128 controls the dosing unit 112 to dose the treatment fluid into the decomposition chamber 108. The treatment fluid delivery system controller 128 may also control the treatment supply unit 116.

[0049] The treatment fluid delivery system controller 128 includes a processing circuit 130. The processing circuit 130 includes a processor 132 and a memory 134. The processor 132 may include a microprocessor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), etc., or combinations thereof. The memory 134 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. This memory 134 may include a memory chip, Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), flash memory, or any 4909-6784-4474 - 11 -Atty. Dkt. No.: 106389-9658other suitable memory from which the treatment fluid delivery system controller 128 can read instructions. The instructions may include code from any suitable programming language. The memory 134 may include various modules that include instructions which are configured to be implemented by the processor 132.

[0050] In various embodiments, the treatment fluid delivery system controller 128 is configured to communicate with a central controller 136 (e.g., engine control unit (ECU), engine control module (ECM), etc.) of an internal combustion engine having the aftertreatment system 100. In some embodiments, the central controller 136 and the treatment fluid delivery system controller 128 are integrated into a single controller.

[0051] In some embodiments, the central controller 136 is communicable with a display device (e.g., screen, monitor, touch screen, heads up display (EIUD), indicator light, etc.). The display device may be configured to change state in response to receiving information from the central controller 136. 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 “SERVICE NEEDED” message, etc.) based on a communication from the central controller 136. By changing state, the display device may provide an indication to a user (e.g., operator, etc.) of a status (e.g., operation, in need of service, etc.) of the treatment fluid delivery system 102.

[0052] The aftertreatment system 100 further includes a catalyst member 138 (e.g., SCR (Selective Catalytic Reduction) catalyst member, etc.) disposed downstream of the decomposition chamber 108. As a result, the treatment fluid is injected upstream of the catalyst member 138 such that the catalyst member 138 receives a mixture of the treatment fluid and exhaust. The treatment fluid droplets undergo the processes of evaporation, thermolysis, and hydrolysis to form non-NOx emissions (e.g., gaseous ammonia, etc.) within the exhaust conduit system 104.

[0053] The catalyst member 138 includes a catalyst member inlet that is in fluid communication with the decomposition chamber 108 from which exhaust and treatment fluid are received and a catalyst member outlet that is in fluid communication with an exhaust4909-6784-4474 - 12 -Atty. Dkt. No.: 106389-9658conduit outlet 140 of the exhaust conduit system 104. The exhaust conduit outlet 140 may release the treated exhaust into an ambient environment or another treatment system.

[0054] The aftertreatment system 100 may further include an oxidation catalyst member 139 (e.g., a diesel oxidation catalyst (DOC), ammonia oxidation catalyst (AMOX), etc.) that is in fluid communication with the exhaust conduit system 104 to oxidize hydrocarbons and carbon monoxide in the exhaust. The oxidation catalyst member 139 may be positioned upstream of the catalyst member 138. The oxidation catalyst member 139 may be positioned upstream of the particulate filter 106.

[0055] In some implementations, the particulate filter 106 may be positioned downstream of the decomposition chamber 108. For instance, the particulate filter 106 and the catalyst member 138 may be combined into a single unit. In some implementations, the dosing unit 112 may instead be positioned downstream of a turbocharger or upstream of the turbocharger.

[0056] The aftertreatment system 100 may further include a doser mounting bracket 142 (e.g., mounting bracket, coupler, plate, etc.). The doser mounting bracket 142 couples the dosing unit 112 to a component of the aftertreatment system 100 (e.g., the decomposition chamber 108, etc.). The doser mounting bracket 142 may be configured as an insulator (e.g., vibrational insulator, thermal insulator, etc.). For example, the doser mounting bracket 142 may be configured to mitigate the transfer of heat from the exhaust passing through the exhaust conduit system 104 to the dosing unit 112. In this way, the dosing unit 112 is capable of operating more efficiently. The doser mounting bracket 142 may be configured to mitigate transfer of vibrations from the component of the aftertreatment system 100 to the dosing unit 112. Additionally, the doser mounting bracket 142 is configured to aid in reliable installation of the dosing unit 112. This may decrease manufacturing costs associated with the aftertreatment system 100 and ensure repeated desirable installation of the dosing unit 112.

[0057] In various embodiments, the doser mounting bracket 142 couples the dosing unit 112 to the decomposition chamber 108. In some embodiments, the doser mounting bracket 142 couples the dosing unit 112 to an exhaust conduit of the exhaust conduit system 104. For example, the doser mounting bracket 142 may couple the dosing unit 112 to an exhaust conduit4909-6784-4474 - 13 -Atty. Dkt. No.: 106389-9658of the exhaust conduit system 104 that is upstream of the decomposition chamber 108. In some embodiments, the doser mounting bracket 142 couples the dosing unit 112 to the particulate filter 106 and / or the catalyst member 138. The location of the doser mounting bracket 142 may be varied depending on the application of the aftertreatment system 100. For example, in some aftertreatment systems 100, the doser mounting bracket 142 may be located further upstream than in other aftertreatment systems 100. Furthermore, some aftertreatment systems 100 may include multiple dosing units 112 and therefore may include multiple doser mounting brackets 142.

[0058] The doser mounting bracket 142 couples the decomposition chamber 108 to the dosing unit 112 to provide treatment fluid (e.g., the reductant) to the decomposition chamber 108. The doser mounting bracket 142 is formed from a material which can be a metal, a composite, and / or a stainless steel (e.g., CB6, etc.)

[0059] The aftertreatment system 100 further includes an exhaust heater assembly 170. The exhaust heater assembly 170 is electrically or communicatively coupled to at least one controller (e.g., the central controller 136). The exhaust 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 exhaust heater assembly 170 may be configured to generate heat via energy (e.g., electrical current, etc.). The exhaust heater assembly 170 may be coupled to at least one battery 172, and the exhaust heater assembly 170 is configured to receive electrical current from and return electrical current to the battery 172.

[0060] The exhaust heater assembly 170 may be coupled to the oxidation catalyst member 139. The exhaust heater assembly 170 may be coupled to an inlet of the oxidation catalyst member 139. The exhaust heater assembly 170 provides heat to the oxidation catalyst member 139 to facilitate chemical reactions occurring within the oxidation catalyst member 139 to reduce the exhaust via the treatment fluid.

[0061] The exhaust heater assembly 170 may be disposed upstream, within, around, or downstream of the oxidation catalyst member 139. The exhaust heater assembly 170 may be4909-6784-4474 - 14 -Atty. Dkt. No.: 106389-9658located proximate to the oxidation catalyst member 139 (e.g., less than 1 to 5 times a diameter of the oxidation catalyst member 139 away from the oxidation catalyst member 139, less than 1 to 5. times a diameter of the exhaust heater assembly 170 away from the oxidation catalyst member 139, less than 1 to 5 times a diameter of the exhaust conduit system 104 away from the oxidation catalyst member 139, etc.).

[0062] The exhaust heater assembly 170 is configured to increase temperatures of air, the exhaust, and / or the treatment fluid, which may allow the oxidation catalyst member 139 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 oxidation catalyst member 139 would reach the operating temperature without heating assistance from exhaust heater assembly 170). Increasing the temperature of the exhaust facilitates conversion of the exhaust into less harmful substances, such as carbon dioxide and water, also facilitates oxidation of a portion of particulate matter to reduce total emissions. Increasing the temperature also increases a temperature of the exhaust gas in the oxidation catalyst member 139, facilitating operation of both the particulate filter 106 and the catalyst member 138 downstream of the oxidation catalyst member 139.

[0063] The exhaust heater assembly 170 may be coupled to the catalyst member 138. The exhaust heater assembly 170 may be located downstream of the decomposition chamber 108 and upstream of the catalyst member 138. The exhaust heater assembly 170 may be coupled to an inlet of the catalyst member 138. The exhaust heater assembly 170 provides heat to the catalyst member 138 to facilitate chemical reactions occurring within the catalyst member 138 to reduce the exhaust via the treatment fluid.

[0064] The exhaust heater assembly 170 is configured to increase temperatures of air, the exhaust, and / or the treatment fluid, which may allow the catalyst member 138 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 catalyst member 138 would reach the operating temperature without heating assistance from exhaust 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 fluid and mitigate deposit 4909-6784-4474 - 15 -Atty. Dkt. No.: 106389-9658accumulation in the exhaust conduit system 104. Increasing the temperature of the catalyst member 138 may increase the NOx conversion efficiency of the exhaust aftertreatment.Increasing the temperature of the catalyst member 138 may also burn particulates (e.g., soot) within the catalyst member 138 and clean the catalyst member 138.III. Overview of Example Exhaust Heater Assemblies

[0065] FIGS. 2-18 depict various portions of the aftertreatment system 100, according to various embodiments. As described above, the exhaust heater assembly 170 provides heat to at least one of the catalyst member 138, the oxidation catalyst member 139, or the particulate filter 106 to facilitate treatment of the exhaust.

[0066] The exhaust heater assembly 170 includes a 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 heater 202 is an electrical heater, and includes a resistance coil 204 as shown in FIG. 3, for example. In various embodiments, 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 may be composed of 80% nickel and 20% chromium. The heat generated by the resistance coil 204 is provided to the exhaust within, flowing from, or flowing to, the catalyst member 138.

[0067] The exhaust heater assembly 170 includes a housing 206. The heater 202 is located in the housing and removably coupled to the housing 206. In some embodiments, the housing 206 acts as a heat shield that absorbs, reflects, or dissipates heat generated by the heater 202. The housing 206 is configured to mitigate heat transfer of the heater 202 to various components of the aftertreatment system 100 (e.g., the dosing unit 112) and direct heat generated by the resistance coil 204 to the catalyst member 138. In some embodiments, the housing 206 is coupled to the catalyst member 138.

[0068] The housing 206 includes an outer surface 208. The outer surface 208 is not in contact with the heater 202. The housing 206 also includes an inner peripheral surface 210. The inner peripheral surface 210 faces the heater 202 when the heater 202 is located in the housing 206. The inner peripheral surface 210 extends around and is centered on a center axis Al. In 4909-6784-4474 - 16 -Atty. Dkt. No.: 106389-9658some embodiments, the heater 202 is at least partially in contact with the inner peripheral surface 210. The housing 206 has a cylindrical shape. The housing 206 includes an opening 212. The opening 212 extends from the inner peripheral surface 210 to the outer surface 208.

[0069] As shown in, for example, FIGS. 2-3, the exhaust heater assembly 170 includes an exhaust heater current adaptor 302. The exhaust heater current adaptor 302 is electrically coupled to the battery 172 and the heater 202. The exhaust heater current adaptor 302 is configured to facilitate provision of electrical power to the heater 202 by receiving electrical current from the battery 172 and providing electrical current to the battery 172. For example, the electrical current begins at the battery 172, travels through the exhaust heater current adaptor 302 to the resistance coil 204, and back through the exhaust heater current adaptor 302 to the battery 172.IV. First Embodiment of the Exhaust Heater Current Adaptor

[0070] Referring now to FIGS. 2-4, 6-7, and 10, the exhaust heater current adaptor 302 is removably coupled to the heater 202. In some embodiments, as seen in FIGS. 2 and 6, the housing 206 includes a current adaptor support 214. The current adaptor support 214 is coupled to the outer surface 208 and removably coupled to the exhaust heater current adaptor 302. The current adaptor support 214 extends from the outer surface 208 at a first angle al between 60 to 80 degrees, inclusive.

[0071] As seen in, for example, FIGS. 6-7, the exhaust heater current adaptor 302 includes a first cable 304. The first cable 304 is centered on a first axis A2. The first cable 304 includes a first end 306 electrically coupled to the heater 202 and a second end 308 electrically coupled to the battery 172. In some embodiments, the first end 306 is welded to the heater 202.

[0072] The exhaust heater current adaptor 302 includes a first electrical conduit 310. The second end 308 is removably, electrically coupled to the battery 172 via the first electrical conduit 310. The first electrical conduit 310 is electrically coupled to the battery 172 and provides electrical current to and receives electrical current from the first cable 304. The first electrical conduit 310 includes a first portion 312 and a second portion 314. The first portion 312 is electrically coupled to and in contact with the second end 308. The first portion 312 4909-6784-4474 - 17 -Atty. Dkt. No.: 106389-9658extends from the second end 308 at a second angle a2 between 20 to 50 degrees, inclusive, relative to the first axis A2. The second portion 314 is electrically coupled to the battery 172. The second portion 314 is contiguous with the first portion 312 and extends at a third angle a3 between 20 to 40 degrees, inclusive, relative to the first portion 312. In some embodiments, the second portion 314 extends from the first portion 312 parallel to and offset from the first axis A2. In some embodiments, the first electrical conduit 310 extends from the second end 308 along the first axis A2.

[0073] The exhaust heater current adaptor 302 also includes a first connector 316. The first electrical conduit 310 is removably coupled to the first cable 304 by the first connector 316. The first connector 316 is removably coupled to both the first cable 304 and the first electrical conduit 310. The first connector 316 extends around the second end 308. The first connector 316 electrically couples and decouples the first electrical conduit 310 and the first cable 304.

[0074] The exhaust heater current adaptor 302 also includes a first cable gland 318. The first cable gland 318 is configured to clamp the first cable 304 to secure and mitigate movement of the first cable 304. The first cable gland 318 is removably coupled to the first cable 304. The first cable gland 318 includes an aperture 319. The first cable 304 extends through the aperture 319. The first cable gland 318 is in contact with the outer surface 208. Both the first cable 304 and the first cable gland 318 extend through the opening 212. The first cable gland 318 is located closer to the first end 306 than the second end 308.

[0075] The exhaust heater current adaptor 302 includes a second cable 320. The second cable 320 is centered on a second axis A3. The second cable 320 includes a first end 322 and a second end 324. The first end 322 is electrically coupled to the heater 202 while the second end 324 is electrically coupled to the battery 172. In some embodiments, the first end 322 is welded to the heater 202. In some embodiments, as seen in, for example, FIG. 6, the current adaptor support 214 extends at least partially around the first cable 304 and the second cable 320.

[0076] The exhaust heater current adaptor 302 includes a second electrical conduit 326. The second end 324 is removably, electrically coupled to the battery 172 via the second electrical conduit 326. The second electrical conduit 326 is electrically coupled to the battery 172 and4909-6784-4474 - 18 -Atty. Dkt. No.: 106389-9658provides electrical current to and receives electrical current from the second cable 320. The second electrical conduit 326 includes a first portion 325 and a second portion 327. The first portion 325 is electrically coupled to and in contact with the second end 324. The first portion 325 extends from the second end 324 at the second angle a2 between 20 to 50 degrees, inclusive, relative to the second axis A3. The second portion 327 is electrically coupled to the battery 172. The second portion 327 is contiguous with the first portion 325 and extends at the third angle a3 between 20 to 40 degrees, inclusive, relative to the first portion 325. In some embodiments, the second portion 327 extends from the first portion 325 parallel to and offset from the second axis A3. In some embodiments, the second electrical conduit 326 extends from the second end 324 along the second axis A3.

[0077] The exhaust heater current adaptor 302 also includes a second connector 328. The second electrical conduit 326 is removably coupled to the second cable 320 by the second connector 328. The second connector 328 is removably coupled to both the second cable 320 and the second electrical conduit 326. The second connector 328 extends around the second end 324. The second connector 328 electrically couples and decouples the second electrical conduit 326 and the second cable 320.

[0078] The exhaust heater current adaptor 302 also includes a second cable gland 330. The second cable gland 330 is configured to clamp the second cable 320 to secure and mitigate movement of the second cable 320. The second cable gland 330 is removably coupled to the second cable 320. The second cable gland 330 includes an aperture 332. The second cable 320 extends through the aperture 332. The second cable gland 330 is in contact with the outer surface 208. Both the second cable 320 and the second cable gland 330 extend through the opening 212. The second cable gland 330 is located closer to the first end 322 than the second end 324.

[0079] To remove the heater 202 from the housing 206, both the first cable gland 318 and the second cable gland 330 are removed from the first cable 304 and the second cable 320. The first cable 304 and the second cable 320 are also disconnected from the first connector 316 and the second connector 328, respectively.4909-6784-4474 - 19 -Atty. Dkt. No.: 106389-9658V. Overview of Mounting Assemblies

[0080] As seen in, for example. FIGS. 4-5 and 10, to couple and remove the heater 202 from the housing 206, the exhaust heater assembly 170 includes a plurality of mounting assemblies. The exhaust heater assembly 170 includes a first mounting assembly 402 that couples the heater 202 to the inner peripheral surface 210. The first mounting assembly 402 is in contact with the heater 202 and the housing 206. The exhaust heater assembly 170 also includes a second mounting assembly 502 that couples the heater 202 to the inner peripheral surface 210. The second mounting assembly 502 is in contact with the heater 202 and the housing 206. A first line LI extends from the center axis through the first mounting assembly 402. A second line L2 extends from the center axis through the second mounting assembly 502. On a cross-section Cl perpendicular to the center axis Al, a fourth angle a4 is in a range of 70 to 140 degrees, inclusive. For example, the fourth angle a4 between the first line LI and the second line L2 is 90 degrees.

[0081] The exhaust heater assembly 170 includes a third mounting assembly 602 that couples the heater 202 to the inner peripheral surface 210. The third mounting assembly 602 is in contact with the heater 202 and the housing 206. A third line L3 extends from the center axis through the third mounting assembly 602. A fifth angle a5 between the third line L3 and the second line L2 is in a range of 70 to 140 degrees, inclusive. For example, the fifth angle a5 is 90 degrees.

[0082] In some embodiments, the exhaust heater assembly 170 includes a fourth mounting assembly 702 that couples the heater 202 to the inner peripheral surface 210. The fourth mounting assembly 702 is in contact with the heater 202 and the housing 206. A fourth line L4 extends from the center axis through the fourth mounting assembly 702. A sixth angle a6 between the fourth line L4 and the third line L3 is in a range of 70 to 140 degrees, inclusive. For example, the sixth angle a6 is 90 degrees. A seventh angle a7 between the fourth line L4 and the first line LI is in a range of 70 to 140 degrees, inclusive. For example, the fourth angle a4, the fifth angle a5, the sixth angle a6, and the seventh angle a7 are all 90 degrees. The first mounting assembly 402, the second mounting assembly 502, the third mounting assembly 602, and the fourth mounting assembly 702 can be evenly spaced apart (e.g., by 90 degrees) around 4909-6784-4474 - 20 -Atty. Dkt. No.: 106389-9658the inner peripheral surface 210. In some embodiments, the fourth angle a4, the fifth angle a5, the sixth angle a6, and the seventh angle a 7 are different. For example, the fourth angle a4 and the fifth angle a5 are 120 degrees while the sixth angle a6 and the seventh angle a 7 are 60 degrees.

[0083] Each of the mounting assemblies includes a weld nut. For example, the first mounting assembly 402 includes a first weld nut 410. In this case, the housing 206 includes a first housing aperture 216. The first housing aperture 216 extends through the inner peripheral surface 210. The first weld nut 410 is disposed in the first housing aperture 216 and coupled to the housing 206. The first weld nut 410 is in contact with the housing 206. The first weld nut 410 includes a first weld nut aperture 412.VI. Configurations of Mounting Assemblies including Bearings

[0084] Referring now to FIGS. 4-5, in some embodiments, the first mounting assembly 402 further includes a first bearing 414. In this case, the heater 202 includes a first recess 218. The first recess 218 is located below the first housing aperture 216. The first recess 218 enables use of the first weld nut 410 and the first bearing 414 such that a diameter of the heater 202 is maximized relative to a diameter of the inner peripheral surface 210. As such, the cross-sectional area of heat flow of the heater 202 is maximized, providing optimal heating to the catalyst member 138. The first bearing 414 is disposed in the first recess 218. The first bearing 414 defines a first cavity 416.

[0085] The first mounting assembly 402 also includes a first screw 418 that is removably coupled to the first weld nut 410. The first screw 418 extends at least partially through the first housing aperture 216. The first screw 418 enables coupling and removal of the heater 202 from the housing 206. In some embodiments, the first screw 418 is in contact with both the first bearing 414 and the first weld nut 410. The first screw 418 includes a first portion 420 and a second portion 422. The first portion 420 includes a first threaded portion 421 that is threadedly coupled to the first weld nut aperture 412. The first portion 420 extends through the first weld nut aperture 412. The second portion 422 is contiguous with the first portion 420 and has a conical shape. The second portion 422 contacts the first bearing 414 in the first cavity 416.4909-6784-4474 - 21 -Atty. Dkt. No.: 106389-9658

[0086] The second mounting assembly 502 includes a second weld nut 510. In this case, the housing 206 includes a second housing aperture 219. The second housing aperture 219 extends through the inner peripheral surface 210. The second weld nut 510 is disposed in the second housing aperture 219 and coupled to the housing 206. The second weld nut 510 is in contact with the housing 206. The second weld nut 510 includes a second weld nut aperture 512.

[0087] In some embodiments, the second mounting assembly 502 further includes a second bearing 514. In this case, the heater 202 includes a second recess 220. The second recess 220 is located below the second housing aperture 219. The second recess 220 enables use of the second weld nut 510 and the second bearing 514 such that a diameter of the heater 202 is maximized relative to a diameter of the inner peripheral surface 210. As such, the cross-sectional area of heat flow of the heater 202 is maximized, providing optimal heating to the catalyst member 138. The second bearing 514 is disposed in the second recess 220. The second bearing 514 defines a second cavity 516.

[0088] The second mounting assembly 502 also includes a second screw 518 that is removably coupled to the second weld nut 510. The second screw 518 enables coupling and removal of the heater 202 from the housing 206. The second screw 518 extends at least partially through the second housing aperture 219. In some embodiments, the second screw 518 is in contact with both the second bearing 514 and the second weld nut 510. The second screw 518 includes a first portion 520 and a second portion 522. The first portion 520 includes a second threaded portion 521 that is threadedly coupled to the second weld nut aperture 512. The first portion 520 extends through the second weld nut aperture 512. The second portion 522 is contiguous with the first portion 520 and has a conical shape. The second portion 522 contacts the second bearing 514 in the second cavity 516.

[0089] The third mounting assembly 602 includes a third weld nut 610. In this case, the housing 206 includes a third housing aperture 222. The third housing aperture 222 extends through the inner peripheral surface 210. The third weld nut 610 is disposed in the third housing aperture 222 and coupled to the housing 206. The third weld nut 610 is in contact with the housing 206. The third weld nut 610 includes a third weld nut aperture 612.4909-6784-4474 - 22 -Atty. Dkt. No.: 106389-9658

[0090] In some embodiments, the third mounting assembly 602 further includes a third bearing 614. In this case, the heater 202 includes a third recess 224. The third recess 224 is located below the third housing aperture 222. The third recess 224 enables use of the third weld nut 610 and the third bearing 614 such that a diameter of the heater 202 is maximized relative to a diameter of the inner peripheral surface 210. As such, the cross-sectional area of heat flow of the heater 202 is maximized, providing optimal heating to the catalyst member 138. The third bearing 614 is disposed in the third recess 224. The third bearing 614 defines a third cavity 616.

[0091] The third mounting assembly 602 also includes a third screw 618 that is removably coupled to the third weld nut 610. The third screw 618 enables coupling and removal of the heater 202 from the housing 206. The third screw 618 extends at least partially through the third housing aperture 222. In some embodiments, the third screw 618 is in contact with both the third bearing 614 and the third weld nut 610. The third screw 618 includes a first portion 620 and a second portion 622. The first portion 620 includes a third threaded portion 621 that is threadedly coupled to the third weld nut aperture 612. The first portion 620 extends through the third weld nut aperture 612. The second portion 622 is contiguous with the first portion 620 and has a conical shape. The second portion 622 contacts the third bearing 614 in the third cavity 616.

[0092] In embodiments where the exhaust heater assembly 170 includes the fourth mounting assembly 702, the fourth mounting assembly 702 includes a fourth weld nut 710. In this case, the housing 206 includes a fourth housing aperture 226 that extends through the inner peripheral surface 210. The fourth weld nut 710 is disposed in the fourth housing aperture 226 and coupled to the housing 206. The fourth weld nut 710 is in contact with the housing 206. The fourth weld nut 710 includes a fourth weld nut aperture 712.

[0093] In some embodiments, the fourth mounting assembly 702 further includes a fourth bearing 714. In this case, the heater 202 includes a fourth recess 228. The fourth recess 228 is located below the fourth housing aperture 226. The fourth recess 228 enables use of the fourth weld nut 710 and the fourth bearing 714 such that a diameter of the heater 202 is maximized relative to a diameter of the inner peripheral surface 210. As such, the cross-sectional area of heat flow of the heater 202 is maximized, providing optimal heating to the catalyst member 138.4909-6784-4474 - 23 -Atty. Dkt. No.: 106389-9658The fourth bearing 714 is disposed in the fourth recess 228. The fourth bearing 714 defines a fourth cavity 716.

[0094] The fourth mounting assembly 702 also includes a fourth screw 718 that is removably coupled to the fourth weld nut 710. The fourth screw 718 enables coupling and removal of the heater 202 from the housing 206. The fourth screw 718 extends at least partially through the fourth housing aperture 226. In some embodiments, the fourth screw 718 is in contact with both the fourth bearing 714 and the fourth weld nut 710. The fourth screw 718 includes a first portion 720 and a second portion 722. The first portion 720 includes a fourth threaded portion 721 that is threadedly coupled to the fourth weld nut aperture 712. The first portion 720 extends through the fourth weld nut aperture 712. The second portion 722 is contiguous with the first portion 720 and has a conical shape. The second portion 722 contacts the fourth bearing 714 in the fourth cavity 716.

[0095] To remove the heater 202 from the housing 206, in addition to removing, for example, the first cable gland 318 and the second cable gland 330, the first screw 418, the second screw 518, the third screw 618, and in some embodiments the fourth screw 718 are decoupled from the first weld nut 410, the second weld nut 510, the third weld nut 610, and in some embodiments, the fourth weld nut 710 and removed from the first housing aperture 216, the second housing aperture 219, the third housing aperture 222, and in some embodiments, the fourth housing aperture 226, respectively.VII. Configurations of Mounting Assemblies including an Adaptor

[0096] As seen in FIGS. 8-9, in some embodiments, the housing 206 includes an adaptor 230. The adaptor 230 provides additional securement of the heater 202 to the housing 206. The adaptor 230 includes a first wall 232 coupled to and extending from the inner peripheral surface 210. For example, the first wall 232 is contiguous with the inner peripheral surface 210. The first wall 232 extends at an eighth angle a8 from the inner peripheral surface 210 at a range between 30 to 70 degrees, inclusive, relative to the inner peripheral surface 210. The adaptor 230 also includes a first gasket 234 in contact with the first wall 232. The adaptor 230 includes a first flange portion 236 in contact with the first gasket 234 and extending to the heater 202.4909-6784-4474 - 24 -Atty. Dkt. No.: 106389-9658The first flange portion 236 is configured to compress the first gasket 234 towards the first wall 232. The adaptor 230 includes a second wall 238. The second wall 238 is contiguous with the first wall 232 and extends away from the heater 202.

[0097] In the cases that the housing 206 includes the adaptor 230, the heater 202 does not include the first recess 218, the second recess 220, the third recess 224, or, in some embodiments, the fourth recess 228 as seen in, for example, FIGS. 10-11. In this embodiment, the first screw 418 does not include the first portion 420 or the second portion 422, and instead, includes a first head 424, a first shaft 426, and a first ball 428. In this embodiment, a diameter of the first housing aperture 216 is greater than the first housing aperture 216 including the first recess 218. In this case, the first mounting assembly 402 includes a first weld nut 429 with a diameter greater than the first weld nut 410. The first weld nut 429 includes a first weld nut aperture 431. The first head 424 is located outside the first weld nut 429. The first shaft 426 is contiguous with the first head 424 and includes a first threaded portion 427. The first shaft 426 is threadedly coupled to the first weld nut aperture 431 via the first threaded portion 427. The first screw 418 also includes a first ball 428. The first ball 428 is coupled to the first shaft 426 and is in contact with the heater 202 such that the first weld nut 429 is separated from the heater 202.

[0098] In the embodiments of the exhaust heater assembly 170 including the adaptor 230, the second screw 518 does not include the first portion 520 or the second portion 522, and instead, includes a second head 524, a second shaft 526, and a second ball 528. In this embodiment, a diameter of the second housing aperture 219 is greater than the second housing aperture 219 including the second recess 220. In this case, the second mounting assembly 502 includes a second weld nut 529 with a diameter greater than the second weld nut 510. The second weld nut 529 includes a second weld nut aperture 531. The second head 524 is located outside the second weld nut 529. The second shaft 526 is contiguous with the second head 524 and includes a second threaded portion 527. The second shaft 526 is threadedly coupled to the second weld nut aperture 531 via the second threaded portion 527. The second screw 518 also includes a second ball 528. The second ball 528 is coupled to the second shaft 526 and is in contact with the heater 202 such that the second weld nut 529 is separated from the heater 202.4909-6784-4474 - 25 -Atty. Dkt. No.: 106389-9658

[0099] In the embodiments of the exhaust heater assembly 170 including the adaptor 230, the third screw 618 does not include the first portion 620 or the second portion 622, and instead, includes a third head 624, a third shaft 626, and a third ball 628. In this embodiment, a diameter of the third housing aperture 222 is greater than the third housing aperture 222 including the third recess 224. In this case, the third mounting assembly 602 includes a third weld nut 629 with a diameter greater than the third weld nut 610. The third weld nut 629 includes a third weld nut aperture 631. The third head 624 is located outside the third weld nut 629. The third shaft 626 is contiguous with the third head 624 and includes a third threaded portion 627. The third shaft 626 is threadedly coupled to the third weld nut aperture 631 via the third threaded portion 627. The third screw 618 also includes a third ball 628. The third ball 628 is coupled to the third shaft 626 and is in contact with the heater 202 such that the third weld nut 629 is separated from the heater 202.

[0100] In the embodiments of the exhaust heater assembly 170 that includes the adaptor 230 and the fourth mounting assembly 702, the fourth screw 718 does not include the first portion 720 or the second portion 722, and instead, includes a fourth head 724, a fourth shaft 726, and a fourth ball 728. In this embodiment, a diameter of the fourth housing aperture 226 is greater than the fourth housing aperture 226 including the fourth recess 228. In this case, the fourth mounting assembly 702 includes a fourth weld nut 729 with a diameter greater than the fourth weld nut 710. The fourth weld nut 729 includes a fourth weld nut aperture 731. The fourth head 724 is located outside the fourth weld nut 729. The fourth shaft 726 is contiguous with the fourth head 724 and includes a fourth threaded portion 727. The fourth shaft 726 is threadedly coupled to the fourth weld nut aperture 731 via the fourth threaded portion 727. The fourth screw 718 also includes a fourth ball 728. The fourth ball 728 is coupled to the fourth shaft 726 and is in contact with the heater 202 such that the fourth weld nut 729 is separated from the heater 202.VIII. Second Embodiment of the Exhaust Heater Current Adaptor

[0101] FIGS. 12-18 depict various portions of another example of the exhaust heater assembly 170, according to various embodiments. In this embodiment, the exhaust heater4909-6784-4474 - 26 -Atty. Dkt. No.: 106389-9658current adaptor 302 includes a plate 334. The plate 334 is coupled to the housing 206. In this embodiment, the exhaust heater assembly 170 does not include the current adaptor support 214.

[0102] The plate 334 includes a first side 336, and a second side 338 opposite the first side 336. The first side 336 faces the heater 202 while the second side 338 faces away from the heater 202. As seen in, for example, FIG. 18, the first side 336 includes a first conductor 340 and a second conductor 342. Both the first conductor 340 and the second conductor 342 are electrically coupled to the heater 202 (e.g., the resistance coil 204). The second conductor 342 is not in contact with the first conductor 340. The first conductor 340 has a straight shape while the second conductor 342 is curved. A length of the first conductor 340 is less than a length of the second conductor 342. In some embodiments, the first conductor 340 is located at least partially above the second conductor 342. A location and size of the first conductor 340 and the second conductor 342 are to ensure that wires (as described further herein) do not overlap. The wires are placed at equal angles apart from each other around the heater 202.

[0103] The exhaust heater current adaptor 302 further includes a first cable 344 and a second cable 346 as seen in, for example, FIG. 17. The first cable 344 and the second cable 346 are coupled to the second side 338. The exhaust heater current adaptor 302 includes a cable box 348. A portion 350 of the first cable 344 and a portion 352 of the second cable 346 are located in the cable box 348. The cable box 348 is coupled to the second side 338. The cable box 348 includes a first aperture 351 and a second aperture 353. The first cable 344 extends through the first aperture 351 and the second cable 346 extends through the second aperture 353.

[0104] The first cable 344 is centered on a third axis A4. The first cable 344 includes a first end 354 and a second end 356. The first end 354 extends through the plate 334 and is electrically coupled to the first conductor 340. The first end 354 extends at a ninth angle a9 between 70 to 120 degrees, inclusive, relative to the third axis A4. The second end 356 is electrically coupled to the battery 172. A length of the first cable 344 is greater than a length of the second cable 346.

[0105] The second cable 346 is centered on a fourth axis A5 that is parallel to an offset from the third axis A4. The second cable 346 includes a first end 358 and a second end 360. The first4909-6784-4474 - 27 -Atty. Dkt. No.: 106389-9658end 358 extends through the plate 334 and is electrically coupled to the second conductor 342. The first end 358 extends at a tenth angle alO between 70 to 120 degrees, inclusive, relative to the fourth axis A5. The second end 360 is electrically coupled to the battery 172.

[0106] To electrically couple the resistance coil 204 to the first conductor 340 and the second conductor 342, the resistance coil 204 includes a first wire 240 and a second wire 242. In some embodiments, the resistance coil 204 includes a third wire 244 and a fourth wire 246. For example, the heater 202 including 5 kW includes the resistance coil 204 with the first wire 240, the second wire 242, the third wire 244, and the fourth wire 246. The heater 202 including 10 kW would duplicate the first wire 240, the second wire 242, the third wire 244, and the fourth wire 246 to a total of eight wires, all equally spaced apart around the heater 202. The first wire 240, the second wire 242, and in some embodiments, the third wire 244 and the fourth wire 246 extend from the heater 202 towards the plate 334. The first wire 240, the second wire 242, and in some embodiments, the third wire 244 and the fourth wire 246 are electrically coupled to the first cable 344 and the second cable 346 via the first conductor 340 and the second conductor 342.

[0107] The first conductor 340 includes a first connection point 362 and a second connection point 364. The second conductor 342 includes a third connection point 366 and a fourth connection point 368. The first wire 240 electrically couples to the first conductor 340 at either the first connection point 362 or the second connection point 364. The second wire 242 electrically couples at either the third connection point 366 or the fourth connection point 368. For example, the first wire 240 electrically couples to the first conductor 340 at the first connection point 362 and the second wire 242 electrically couples to the second conductor 342 at the third connection point 366.

[0108] In some embodiments, the third wire 244 electrically couples to the first conductor 340 at either the first connection point 362 or the second connection point 364. The fourth wire 246 electrically couples at either the third connection point 366 or the fourth connection point 368. For example, the first wire 240 electrically couples to the first conductor 340 at the first connection point 362, the second wire 242 electrically couples to the second conductor 342 at the third connection point 366, the third wire 244 electrically couples to the first conductor 340 4909-6784-4474 - 28 -Atty. Dkt. No.: 106389-9658at the second connection point 364, and the fourth wire 246 electrically couples to the second conductor 342 at the fourth connection point 368.

[0109] For example, electrical current provided by the battery 172 travels through the first cable 344 to the first conductor 340 and to the resistance coil 204 via at least the first wire 240. The electrical current then returns from the resistance coil 204 via at least the second wire 242 through the second conductor 342 and through the second cable 346 back to the battery 172.

[0110] In the embodiments of the exhaust heater current adaptor 302 including the plate 334, the exhaust heater current adaptor 302 also includes a clamp 370 (e.g., a v-band clamp, v-band clamped joint). The clamp 370 secures the plate 334 to the housing 206. To remove the heater 202 from the housing 206, the clamp 370 is disconnected from the housing 206. The first screw 418, the second screw 518, the third screw 618, and in some embodiments, the fourth screw 718 are also removed from the first mounting assembly 402, the second mounting assembly 502, the third mounting assembly 602, and in some embodiments, the fourth mounting assembly 702, respectively, to remove the heater 202 from the housing 206. The plate 334 is then decoupled from the housing 206, and the heater 202 along with the first wire 240, the second wire 242, the third wire 244, and the fourth wire 246 may be removed.IX. Additional Configurations of Example Embodiments

[0111] As described above, in some embodiments, the exhaust heater assembly 170 includes the exhaust heater current adaptor 302 as seen in, for example, FIGS. 6-7, along with the first mounting assembly 402, the second mounting assembly 502, the third mounting assembly 602, and the fourth mounting assembly 702 as seen in, for example, FIGS. 4-5.

[0112] In some embodiments, the exhaust heater assembly 170 includes the exhaust heater current adaptor 302 as seen in, for example, FIGS. 6-7, along with the adaptor 230 as seen in FIGS. 8-9 and the first mounting assembly 402, the second mounting assembly 502, the third mounting assembly 602, and the fourth mounting assembly 702 as seen in, for example, FIGS.10-11.4909-6784-4474 - 29 -Atty. Dkt. No.: 106389-9658

[0113] In the embodiment as shown in FIGS. 12-18, the exhaust heater assembly 170 includes the plurality of mounting assemblies as described with reference to FIGS. 4-5. For example, the exhaust heater assembly 170 includes the first mounting assembly 402, the second mounting assembly 502, and the third mounting assembly 602. In some embodiments, the exhaust heater assembly 170 includes the fourth mounting assembly 702. The first mounting assembly 402, the second mounting assembly 502, the third mounting assembly 602, and the fourth mounting assembly 702 include the first screw 418, the second screw 518, the third screw 618, and the fourth screw 718 including the second portion 422, the second portion 522, the second portion 622, and the second portion 722, respectively.X. Configuration of Example Embodiments

[0114] 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.

[0115] 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.4909-6784-4474 - 30 -Atty. Dkt. No.: 106389-9658

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.4909-6784-4474 - 31 -

Claims

Atty. Dkt. No.: 106389-9658WHAT IS CLAIMED IS:

1. An exhaust heater assembly comprising:a housing comprising an outer surface and an inner peripheral surface;a heater removably coupled to the housing;a plurality of mounting assemblies coupling the heater to the inner peripheral surface; andan exhaust heater current adaptor removably coupled to the outer surface and the heater, the exhaust heater current adaptor configured to facilitate provision of electrical power to the heater, the exhaust heater current adaptor comprising:a first cable comprising a first end and a second end opposite the first end, the first end electrically coupled to the heater,a first connector removably coupled to and extending around the second end, anda first cable gland removably coupled to the first cable and comprising an aperture, the first cable extending through the aperture.

2. The exhaust heater assembly according to claim 1, wherein:the first cable is centered on a first axis; andthe exhaust heater current adaptor further comprises:a second cable comprising a first end and a second end opposite the first end, the second cable centered on a second axis parallel to and offset from the first axis, the first end electrically coupled to the heater,a second connector removably coupled to and extending around the second end, anda second cable gland removably coupled to the second cable and comprising an aperture, the second cable extending through the aperture.

3. The exhaust heater assembly according to claim 2, wherein:the exhaust heater current adaptor further comprises:4909-6784-4474 32Atty. Dkt. No.: 106389-9658a first electrical conduit removably coupled with a battery and the first cable via the first connector, the first electrical conduit to provide and receive electrical current from the heater via the first cable, anda second electrical conduit removably coupled with the battery and the second cable via the second connector, the second electrical conduit to provide and receive electrical current from the heater via the second cable.

4. The exhaust heater assembly according to claim 2, wherein the housing includes an opening extending from the inner peripheral surface to the outer surface, the first cable gland and the second cable gland extending through the opening.

5. The exhaust heater assembly according to claim 1, wherein:the inner peripheral surface extends around and is centered on a center axis;the plurality of mounting assemblies comprise a first mounting assembly, a second mounting assembly, and a third mounting assembly;in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the first mounting assembly and a line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive; and an angle between a line extending from the center axis through the third mounting assembly and the line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive.

6. The exhaust heater assembly according to claim 5, wherein the exhaust heater assembly comprises a fourth mounting assembly coupled to the inner peripheral surface, wherein, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the fourth mounting assembly and the line extending from the center axis through the third mounting assembly is in a range of 70 to 140 degrees, inclusive.

7. The exhaust heater assembly according to claim 1, wherein:the housing comprises a housing aperture extending through the inner peripheral surface; and4909-6784-4474 33Atty. Dkt. No.: 106389-9658each of the plurality of mounting assemblies comprises:a weld nut disposed in the housing aperture and coupled to the housing, the weld nut comprising a weld nut aperture,a bearing coupled to the heater and defining a cavity, anda screw comprising:a first portion comprising a threaded portion that is threadedly coupled to the weld nut aperture, anda second portion contiguous with the first portion, the second portion having a conical shape and contacting the bearing in the cavity.

8. The exhaust heater assembly according to claim 1, wherein:the housing comprises a housing aperture extending through the inner peripheral surface; andeach of the plurality of mounting assemblies comprises:a weld nut disposed in the housing aperture and coupled to the housing, the weld nut comprising a weld nut aperture, anda screw comprising:a head located outside the weld nut and in contact with the housing; a shaft contiguous with the head and comprising a threaded portion that is threadedly coupled to the weld nut aperture; anda ball coupled to the shaft and in contact with the heater such that the weld nut is separated from the heater.

9. The exhaust heater assembly according to claim 8, wherein:the housing comprises an adaptor comprising:a first wall coupled to and extending from the inner peripheral surface, a first gasket in contact with the first wall, anda first flange portion in contact with the first gasket and extending to the heater configured to compress the first gasket towards the first wall.4909-6784-4474 34Atty. Dkt. No.: 106389-965810. The exhaust heater assembly according to claim 1, further comprising a current adaptor support coupled to the outer surface and removably coupled to the exhaust heater current adaptor.

11. An exhaust heater assembly comprising:a housing comprising an outer surface and an inner peripheral surface;a heater removably coupled to the housing;a plurality of mounting assemblies coupling the heater to the inner peripheral surface; andan exhaust heater current adaptor removably coupled to the outer surface and the heater, the exhaust heater current adaptor configured to facilitate provision of electrical power to the heater and comprising:a plate comprising a first side and a second side, the second side opposite to the first side, the first side comprising a first conductor electrically coupled to the heater, and a first cable coupled to the second side comprising a first end, the first end extending through the plate and electrically coupled to the first conductor.

12. The exhaust heater assembly according to claim 11, wherein:the first cable is centered on a first axis;the first side comprises a second conductor not in contact with the first conductor, the second conductor electrically coupled to the heater; andthe exhaust heater current adaptor further comprises a second cable coupled to the second side comprising a first end and centered on a second axis, the second axis parallel to and offset from the first axis, the first end extending through the plate and electrically coupled to the second conductor.

13. The exhaust heater assembly according to claim 12, wherein:the first conductor comprises a first connection point and a second connection point; the second conductor comprises a third connection point and a fourth connection point; and4909-6784-4474 35Atty. Dkt. No.: 106389-9658the heater comprises at least a first wire, a second wire, a third wire, and a fourth wire extending from the heater and electrically coupled to the plate, the first wire electrically coupled at the first connection point, the second wire electrically coupled at the third connection point, the third wire electrically coupled at the second connection point, and the fourth wire electrically coupled at the fourth connection point.

14. The exhaust heater assembly of claim 13, wherein the first conductor has a length less than a length of the second conductor.

15. The exhaust heater assembly of claim 12, further comprising a cable box coupled to the second side of the plate, the cable box including a first aperture and a second aperture, the first cable extending through the first aperture and the second cable extending through the second aperture.

16. The exhaust heater assembly of claim 12, wherein a length of the first cable is greater than a length of the second cable.

17. The exhaust heater assembly according to claim 11, wherein:the housing comprises a housing aperture extending through the inner peripheral surface; andeach of the plurality of mounting assemblies comprises:a weld nut disposed in the housing aperture and coupled to the housing, the weld nut comprising a weld nut aperture,a bearing coupled to the heater and defining a cavity, anda screw comprising:a first portion comprising a threaded portion that is threadedly coupled to the weld nut aperture, anda second portion contiguous with the first portion, the second portion having a conical shape and contacting the bearing in the cavity.

18. The exhaust heater assembly according to claim 11, wherein:4909-6784-4474 36Atty. Dkt. No.: 106389-9658the inner peripheral surface extends around and is centered on a center axis;the plurality of mounting assemblies comprise a first mounting assembly, a second mounting assembly, and a third mounting assembly;in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the first mounting assembly and a line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive; and an angle between a line extending from the center axis through the third mounting assembly and the line extending from the center axis through the second mounting assembly is in a range of 70 to 140 degrees, inclusive.

19. The exhaust heater assembly according to claim 18, wherein the exhaust heater assembly comprises a fourth mounting assembly coupled to the inner peripheral surface, wherein, in a cross-section perpendicular to the center axis, an angle between a line extending from the center axis through the fourth mounting assembly and the line extending from the center axis through the third mounting assembly is in a range of 70 to 140 degrees, inclusive.

20. The exhaust heater assembly according to claim 11, further comprising a clamp removably coupled to the housing and the plate.4909-6784-4474 37

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