Electric exhaust heater

Abstract

The present teachings relate to a heater for an exhaust aftertreatment apparatus, the heater comprising: a) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough; b) one or more heating elements within the housing and held in place by compression. The heater may be suitable for placement upstream of a catalyst of an exhaust aftertreatment apparatus.

Description

Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOELECTRIC EXHAUST HEATERCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 748,818 filed on January 23, 2025, which is incorporated herein by reference in its entirety for all purposes.FIELD

[0002] The present teachings relate to an electric exhaust heater. The present teachings may find particular use in simplifying assembly and providing improved heating of the heater’s heating elements.BACKGROUND

[0003] Generally, internal combustion engines produce an exhaust stream having toxic gases and pollutants within the exhaust stream. Agencies across the world, such as the United States Environmental Protection Agency, have enacted regulations regarding the exhaust emissions, seeking to reduce the toxic gases and pollutants. It is now typical that transportation vehicles (e.g., commercial vehicles, such as trucks) are equipped with exhaust aftertreatment systems configured to remove or reduce the toxic gases and pollutants within the exhaust stream prior to emission of the exhaust stream into the atmosphere. Vehicles having diesel combustion systems are most often equipped with such aftertreatment systems.

[0004] Reactor portions in exhaust systems typically employ a catalyst that reacts with the exhaust stream passing therethrough. The employment of catalysts tends to be temperature dependent in order for the chemical reactants to be sufficiently exposed to a catalyst at a desired reaction temperature to achieve the desired reaction. In other words, the catalyst needs to be at a sufficiently high operating temperature for the desired reaction to take place as an exhaust stream passes therethrough.

[0005] To heat a catalyst to suitable operating temperatures, methods employed today include hydrocarbon dosing, fuel injecting timing methods, electric exhaust heaters, and the like. Electric exhaust heaters are most often located in proximity to and upstream of a catalyst. The heater is configured to raise the temperature of the exhaust stream passing therethrough before the exhaust stream passes through the catalyst. In this manner, the exhaust stream, when passing through the catalyst, also increases the operating temperature of the catalyst.

[0006] Traditionally, electric exhaust heaters include a number of heating elements therein. The heating elements are often assembled to the housing by welding or brazing. Welding attachments often need to maintain higher thicknesses to provide for sufficient durability to handle stress on the joint. This increased thickness results in reduced heating efficiency. Brazing may also be tooFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOexpensive, may require special furnaces and a long cycle time for creating the joint, and may offer a weaker joint than a weld.SUMMARY

[0007] The present teachings relate to a heater for an exhaust aftertreatment apparatus, the heater comprising: a) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough; and b) one or more heating elements held in place by compression.

[0008] The present teachings may relate to a heater for an exhaust aftertreatment apparatus, the heater comprising: a) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough; and b) one or more heating elements within the housing and retained in place by¬ compression; wherein the one or more heating elements include a plurality of heating elements arranged across a width of an interior of the housing; wherein the one or more heating elements have an undulating profile with a wavy texture across a length and / or height of the one or more heating elements; wherein the heater includes a plurality of spacers which are alternatingly arranged with the undulations of the one or more heating elements to form a stack; wherein the heater includes one or more upper conductor plates arranged at an upper end of the one or more heating elements and one or more lower conductor plates arranged at a lower end of the one or more heating elements; and wherein the heater includes one or more upper mounting mats between the housing and the one or more upper conductor plates and one or more lower mounting mats between the housing and the one or more lower conductor plates.

[0009] The present teachings may relate to an exhaust afitertreatment apparatus comprising a heater as taught herein.

[0010] The present teachings may relate to an exhaust aftertreatment apparatus comprising: a) a heater including: i) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough; and ii) one or more heating elements within the housing and retained in place by compression; and b) a catalyst downstream and adjacent to the heater.

[0011] The heater may be an electric exhaust heater.

[0012] The heater may be particularly beneficial in avoiding welding, brazing, and mechanical fasteners for assembling heating elements within the housing by instead relying on compression. This may avoid heat loss, improve heating, reduce or eliminate stressors, simplify assembly, and the like.BRIEF DESCRIPTION OF DRAWINGS

[0013] FIG. 1 is a perspective view of an exhaust aftertreatment apparatus.

[0014] FIG. 2 is a close-up view of a heater within an exhaust aftertreatment apparatus.

[0015] FIG. 3 is a close-up and partially transparent view of a heater within an exhaust aftertreatment apparatus.Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WO

[0016] FIG. 4 is a rear perspective view of a heater.

[0017] FIG. 5 is a front perspective view of a heater.

[0018] FIG. 6 is a cross-sectional view of a heater.

[0019] FIG. 7 is a front view of a heater.

[0020] FIG. 8 is a partially exploded view of a heater.

[0021] FIG. 9 is a perspective view of interior components of a heater.

[0022] FIG. 10 illustrates the heating elements and spacers of a heater.DETAILED DESCRIPTION

[0023] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the present teachings, their principles, and their practical application. The specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the present teachings. The scope of the present teachings should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible, as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0024] Heater

[0025] The present teachings relate to a heater. The heater may be an exhaust heater. The exhaust heater may be an electric exhaust heater or a fuel-fired heater. The heater may function to heat an exhaust stream flowing therethrough, heat a catalyst in close proximity (e.g., indirectly or directly), or both. The heater may function to heat an exhaust stream and / or catalyst to a sufficient operating temperature to support one or more reactions. The heater may be located adjacent to, affixed to, and / or within one or more reactor portions. The heater may be located in proximity to, adjacent to, and / or upstream of a catalyst. The heater may include one or more housings, heating elements, connectors, conductor places, spacers, mounting mats, the like, or a combination thereof.

[0026] The heater may include one or more heating elements. The one or more heating elements may function to be heated, transfer heat to an exhaust stream, or both. The one or more heating elements may be configured to increase surface area, turbulence, thermal conductivity, the like, or a combination thereof.

[0027] The one or more heating elements may be configured to increase the surface area of heating elements and thus increase heat transfer. The one or more heating elements may have a length, thickness, depth, or a combination thereof that is larger than typical heating elements for exhaustFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOheaters. Individual heating elements of the one or more heating elements may have differing surface areas.

[0028] The one or more heating elements may be configured to increase turbulence of an exhaust stream therethrough and thus enhance heat transfer. The one or more heating elements may be formed as one or more U-shaped ribs, one or more undulating strips, one or more corrugated strips, or a combination thereof. A corrugated or undulating strip may be a repetitive pattern of U-shaped ribs integrally connected to one another. The one or more heating elements may include one or more major surfaces and one or more minor surfaces. One or more major surfaces may include two major surfaces. The one or more major surfaces may refer to the opposing larger surfaces of the heating element. One or more minor surfaces may include two minor surfaces. The two minor surfaces may refer to smaller opposing surfaces or edges of the heating element. The two minor surfaces may be referred to as the side edges. The one or more heating elements may have one or more major surfaces which are smooth along their length, are variable in surface texture along their length, or both. Variable may include wavy. For example, the heating elements may be wavy along their length. One or more heating elements may be undulating while also being wavy. The one or more heating elements may also be referred to as one or more heat exchangers.

[0029] The one or more heating elements may be configured to increase thermal conductivity'. By increasing thermal conductive, the heating element(s) may more efficiently and quickly heat the exhaust gas stream. The thermal conductivity may be optimized or increased by the use of one or more materials in the housing, heating elements, conductor plates, spacers, mounting mats, or a combination thereof.

[0030] The one or more heating elements may comprise one or more materials. The one or more materials may be any suitable material for conducting and transferring heat, being able to operate and maintain durability in such heat, or both. The one or more materials may include one or more materials that are electrically conductive, heat conductive, or both. The one or more materials may include one or more metals. The one or more materials may include nickel, chromium, copper, aluminum, stainless steel, the like, or a combination thereof. One example combination is the alloy of nichrome (i.e., a nickel chromium alloy). Nichrome, while not as efficient at heat transfer as other metals, may be durable enough to withstand high operating temperatures, may resist melting and / or corrosion, and may have a sufficiently high electrical resistivity to be suitable for generating heat.

[0031] The one or more heating elements may be arranged within the heater. The one or more heating elements may be arranged to be in the path of an exhaust stream, generally perpendicular to a flow direction of an exhaust stream, or both. The one or more heating elements may be arranged to span a length, width, and / or height of an interior of a heater. The one or more heatingFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOelements may be arranged to extend between conductive elements. The one or more heating elements may extend from one conductive element to an opposing conductive element. The one or more heating elements may have a longitudinal axis parallel to, perpendicular to, or offset from a longitudinal axis of the conductive elements. A conductive element may be a conductor plate. A heating element may extend from an upper conductor plate to an opposing lower conductor plate.

[0032] The one or more heating elements may be affixed within a heater. The one or more heating elements may be affixed into a heater via compression, welding, brazing, soldering, adhesive material, mechanical fasteners, biasing devices, the like, or a combination thereof. The one or more heating elements may be affixed within a heater via compression. The compression may be applied via a compressive force. The compressive force may act towards a central portion of the heater (e.g., the compressive force may push inward on the heater or its components). Compression may be applied by any suitable component. Compression may be applied by the housing, mounting mat(s), conductor plates, threaded fasteners, biasing devices (e.g., springs), and / or the like. The one or more heating elements may be free of attachment into the heater via welding, brazing, soldering, and / or adhesive material. The one or more heating elements may only be attached into the heater via compression. Compression may be applied by one or more mounting mats and / or conductor plates while being free of threaded fasteners or biasing devices; by one or more threaded fasteners while being free of biasing devices or mounting mats; or by one or more biasing devices while being free of threaded fasteners or mounting mats. By being free of additional attachment methods (e.g., threaded fasteners and / or biasing devices) and only being affixed via compression, there may be improved heat transfer to each heating element. The one or more heating elements may be held in place via compression applied by one or more conductive elements (e.g., conductor plates), mounting mats, a housing, threaded fastener(s), biasing device(s). the like, or a combination thereof.

[0033] The one or more heating elements may include a plurality7of heating elements. A plurality7of heating elements may allow for an increased surface area to transfer heat to an exhaust stream passing therethrough. A plurality of heating elements may be arranged in one or more arrays, a staggered pattern, a random pattern, the like, or a combination thereof. A plurality of heating elements may be arranged in one or more arrays that span from one side of the heater to another side of the heater. The one side of the heater to another side of the heater may include a top side to a bottom side and / or one lateral side to another lateral side (e.g., left and right sides and / or front and back sides). A plurality of heating elements may be arranged in an array along a width of an interior of a heater (e.g., side to side), parallel to a longitudinal axis of one or more conductive elements (e.g., conductor plates) (e.g., spaced across same direction as longitudinal axis of one or more conductor plates), parallel to a longitudinal axis of one or more mounting mats (e.g., spacedFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOacross same direction as longitudinal axis of one or more mounting mats), the like, or a combination thereof. A plurality of heating elements may include one or more, two or more, three or more, or even four or more heating elements. A plurality of heating elements may include ten or fewer, eight or fewer, or even six or fewer heating elements.

[0034] The heater may include one or more spacers. One or more spacers may be configured to maintain an overall length and / or height of each heating element, resist a compression force applied to each heating element, apply a counter force opposite a compression force, maintain a height or width of each U-shaped rib or undulation, provide electrical insulation, or a combination thereof. One or more spacers may function as electrical insulators, thus promoting electrical cunent flowing only through the heating elements and not through the spacers. One or more spacers may be located within each undulation of a heating element. One or more spacers may include a plurality of spacers. A number of spacers associated with each heating element may be approximately greater than, less than, or equal to the number of undulations of each heating element. A number of spacers associated with each heating element may be less than or equal to the number of undulations of each heating element. A number of spacers associated with the heater may be less than, equal to, or greater than the number of the one or more heating elements. One or more spacers may have a shape suitable for residing within an undulation, reciprocal to the shape of an undulation, or both. One or more spacers may have a shape which is substantially discshaped, annular, cylindrical, cuboidal, the like, or a combination thereof. For example, one or more spacers may be substantially annular shaped. One or more spacers may have a different shape than one or more other spacers. A plurality of spacers may be arranged as a stack along the length or height of each heating element. A plurality of spacers may be arranged as an alternating stack with one or more undulations of a heating element along the length or height of each heating element.

[0035] One or more spacers may comprise one or more materials. The one or more materials may be configured to withstand the operating temperatures, impart reinforcement to the heating elements at the operating temperatures, not significantly reduce the heat conductivity of the heating elements, enhance heat conductivity within the heating elements, provide electrical insulation to promote electricity flowing through the heating element(s), or a combination thereof. The one or more spacers may comprise one or more materials that are heat conductive. The one or more spacers may comprise one or more materials that are not electrically conductive. The one or more spacers may comprise ceramic, glass, carbon, minerals, metals, composites thereof, alloys thereof, the like, or any combination thereof.

[0036] The heater may include one or more conductive elements. One or more conductive elements may function to transfer electricity, heat, or both to one or more heating elements. One or more conductive elements may function to be affixed to one or more heating elements. One orFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOmore conductive elements may include one or more conductor plates. One or more conductor plates may be arranged at opposing ends of one or more heating elements. One or more conductor plates may include one or more upper conductor plates, one or more lower conductor plates, or both. One or more conductor plates (e.g., upper conductor plate) may be distanced and opposite from one or more other conductor plates (e.g.. lower conductor plate). One or more upper conductor plates may be located at one end (e.g., upper end) of one or more heating elements while one or more lower conductor plates may be located at an opposing end (e.g., lower end) of the one or more heating elements. One or more conductor plates may be associated with a single heating element or span across a plurality of heating elements. One or more conductor plates may be connected to a single or a plurality of heating elements. One or more conductor plates may be connected to a smaller, larger, or equal amount of heating elements as one or more other conductor plates. There may be a same, lesser, or greater number of upper conductor plates as lower conductor plates. For example, there may be twice as many upper conductor plates as lower conductor plates. For example, a pair of upper conductor plates may each be associated with two heating elements while a single lower conductor plate may be associated with each of the four heating elements. One or more conductor plates may have a shape different from or reciprocal to a mounting mat, a cross-section of an interior of the housing, an end of a heating element, or a combination thereof. For example, one or more conductor plates may have a thin and cuboidal shape (e.g., bar-shaped). For example, one or more conductor plates may have aT-shape profile. One or more conductor plates may include one or more extensions. An extension may be a portion of a conductor plate which protrudes away. An extension may function to receive an electrical connection. An extension may include a through-hole for receiving an electrical connection therein. One or more conductor plates may be adjacent to, directly on, spaced from, abut, and / or be stacked on one or more mounting mats. The one or more conductor plates may be stacked below and / or on top of the one or more mounting mats such that the longitudinal axis of the one or more conductor plates is parallel with the longitudinal axis of the one or more mounting mats. For example, a lower conductor plate may be stacked on top of a lower mounting mat, an upper mounting mat may be stacked on top of an upper conductor plate, or both.

[0037] One or more conductor plates may be comprised of one or more materials. The one or more materials may be any suitable material for conducting and transferring heat, being able to operate and maintain durability in such heat, or both. The one or more materials may include one or more materials that are electrically conductive, heat conductive, or both. The one or more materials may include one or more metals. The one or more materials may include nickel, chromium, copper, aluminum, stainless steel, the like, or a combination thereof. One example combination is the alloy of nichrome (i.e., a nickel chromium alloy). Nichrome, while not as efficient at heat transfer asFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOother metals, may be durable enough to withstand high operating temperatures, may resist melting and / or corrosion, and may have a sufficiently high electrical resistivity to be suitable for generating heat. The one or more materials may be any material suitable for the heating element, spacer, or a combination thereof.

[0038] One or more conductor plates may be arranged within the housing. The one or more conductor plates may extend along a width, depth, and / or height of a housing. The one or more conductor plates may be biased toward one or more interior sides of a housing. The one or more conductor plates may be arranged such that a longitudinal axis is substantially parallel with one or more sides (e.g., upper, lower, vertical side, etc.) of an interior of a housing, an array or other arrangement of heating elements, one or more mounting mats, or a combination thereof. The one or more conductor plates may be located between one or more mounting mats and one or more heating elements.

[0039] The heater may include one or more mounting mats. One or more mounting mats may function to apply compression and retain one or more heating elements, conductive elements (e.g., conductor plates), spacers, or a combination thereof; receive compression from a housing; or a combination thereof. One or more mounting mats may function as electrical insulators, such as to promote the flow of electricity to the one or more heating elements One or more mounting mats may insulate one or more heating elements, conductive elements, spacers, or a combination thereof from a housing. One or more mounting mats may be arranged at opposing ends of one or more heating elements, adjacent to one or more conductive elements, abutting one or more conductive elements, or a combination thereof. One or more mounting mats may include one or more upper mounting mats, one or more lower mounting mats, or both. One or more mounting mats (e.g., upper mounting mat) may be distanced and opposite from one or more other mounting mats (e.g., lower mounting mat). One or more mounting mats may have a shape reciprocal to a conductor plate, an arrangement of heating elements, a cross-section of an interior of the housing, or a combination thereof. For example, one or more mounting mats may have a thin and cuboidal shape. The one or more mounting mats may be stacked on the one or more conductor plates such that the longitudinal axis of the one or more mounting mats is parallel with the longitudinal axis of the one or more conductor plates, or both. For example, a lower conductor plate may be stacked on top of a lower mounting mat, an upper mounting mat may be stacked on top of an upper conductor plate, or both. The one or more mounting mats may be a single layer or a plurality of layers. Each layer may be a same or different material from another layer.

[0040] One or more mounting mats may be comprised of one or more materials. The one or more materials may be configured to withstand the operating temperatures, impart reinforcement at operating temperatures, apply a sufficient compressive force, receive a compressive force orFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOcounter force, or a combination thereof. The one or more materials may function as a thermal insulator, acoustic insulator, and / or electrical insulator. The one or more mounting mats may be comprised of one or more materials, which may or may not be heat conductive. The one or more mounting mats may be comprised of one or more materials that are not electrically conductive. The one or more mounting mats may comprise ceramic, glass, carbon, minerals, metals, composites thereof, alloys thereof, the like, or any combination thereof. The material may be reinforced. For example, the material may be a fiber reinforced material. The fibers in the fiber reinforced material may be glass, mineral, carbon, silicone, metal (e.g., aluminum), zirconia, basalt, silica, the like, or a combination thereof. The one or more materials may be fire resistant and / or fireproof.

[0041] One or more mounting mats may be arranged within the housing. The one or more mounting mats may extend along a width, depth, and / or height of a housing. The one or more mounting mats may be biased toward one or more interior sides of a housing. The one or more mounting mats may be located directly adjacent one or more interior sides of a housing. The one or more mounting mats may be located between an interior side of the housing and one or more conductive elements (e.g., conductive plates) and / or one or more heating elements. The one or more mounting mats may be arranged such that a longitudinal axis is substantially parallel with one or more sides (e.g., upper, lower, vertical sides, etc.) of an interior of a housing, an array or other arrangement of heating elements, one or more conductive elements, or a combination thereof.

[0042] A heater may include a housing. A housing may function to house one or more components of the heater, apply a compression force, cooperate with one or more reactor portions, provide a pass through from an exhaust stream, the like, or any combination thereof. One or more components of the heater may include one or more heating elements, one or more connectors, one or more conductor plates, one or more spacers, one or more mounting mates, the like, or a combination thereof.

[0043] Ahousing may comprise one or more housing portions. One or more housing portions may cooperate with one or more other housing portions to form the housing. One or more housing portions may be assembled together, mated, integral with one another, ora combination thereof to form the housing. One or more housing portions may be assembled together via tension fit, mechanical interlocking, fasteners, adhesives, welding, brazing, the like, or a combination thereof. One or more housing portions may be integrally formed with one or more other housing portions. One or more housing portions may include an upper housing portion, lower housing portion, upstream housing portion, a downstream housing portion, or a combination thereof. The one or more housing portions may have one overall shape or be formed of multiple shapes. The housing may have a portion or one or more portions which form a substantially cuboidal shape or portion.Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOFor example, an upper housing portion and lower housing portion may form a cuboidal portion. The upper housing portion and lower housing portion may each have a substantial U-shaped profile. A cuboidal portion may be a central region of the housing. A cuboidal portion may be a portion that stores one or more heating elements, spacers, conductive elements, mounting mats, the like, or a combination thereof. One or both rims (upstream and / or downstream side) of the cuboidal portion may be indented inward, be configured to be received within the upstream and / or downstream housing portions, or both. The upper housing portion, lower housing portion, central region (e.g., cuboidal portion), upstream portion, downstream portion, or a combination thereof may be hollow. A hollow interior may allow for an exhaust stream to pass therethrough. The housing may have one or more portions that are substantially cylindrical and / or conical. The upstream housing portion and / or downstream housing portion may have a shape or transition to a shape substantially reciprocal with a reactor portion adjacent thereto. The upstream housing portion and downstream housing portion may have a cylindrical and / or conical portion on an exterior side. The upstream housing portion and the downstream housing portion may be symmetrical or asymmetrical about the central region. An upstream portion, downstream portion, or both may have a cuboidal cross-section which tapers or otherwise extends into a cylindrical and / or conical portion. The cuboidal cross-section may be configured to mate with the a rim of the cuboidal region, receive the rim therein, or both. The cylindrical and / or conical portion may be hollow. The hollow' interior may allow' for the exhaust stream to enter, exit, or both. The cuboidal cross-section of the upstream portion, dow nstream portion, or both may be reciprocal with the shape of the cuboidal portion and / or the upper portion and second portion when mated. The housing may be an assembly of the upper portion affixed to the lower portion to form a cuboid portion or central region, an upstream portion affixed at one end of the cuboid portion (e.g., at the inlet), and a downstream portion affixed at the opposing end of the cuboid portion (e g., at the outlet). Although the central region is disclosed as having a cuboid shape, it may also be at least partially cylindrical, conical, truncated conical, or other suitable three-dimensional shapes. Although four discrete portions are disclosed which come together to form the housing, it is possible there may be three or even two or even a single discrete portion. For example, the upper housing portion may comprise an upper half of the upstream and downstream portions while the lower housing portion may comprise a lower half of the upstream and downstream portions. As another example, the upstream housing portion may include one upstream section of the cuboid region while the downstream housing portion includes a downstream housing section of the cuboid region (e.g., free of upper and lower housing regions).Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WO

[0044] The housing may be assembled after or before placement of the one or more heating elements, spacers, conductive elements, and / or mounting mats into or onto one or more housing portions.

[0045] For example, one or more lower mounting mats may be placed onto an interior lower surface of a lower housing portion. Then one or more lower conductive plates may be placed atop the lower mounting mat(s). A plurality of heating elements with spacers included therein may then be placed atop the one or more lower conductive plates. One or more lower ends of the heating elements may be placed in direct contact with the lower conductive plate(s). Thereafter, one or more upper conductive plates may be located atop one or more upper ends of the one or more heating elements. One or more upper ends of the heating elements may be placed in direct contact with the upper conductive plate(s). One or more upper mounting mats may then be placed atop the one or more upper conductive plates. Then an upper housing portion may be placed atop the upper conductive plate(s). One or more side flanges of the upper housing portion may be inserted into one or more side flanges of the lower housing portion. The upper housing portion may compress the interior components and mate with the lower housing portion. Compression may be applied by temporary tooling and / or the upstream and / or downstream housing portions. The upstream and / or downstream reactor portions may then be affixed about a rim of the central housing portion, upper housing portion, and / or downstream housing portion.

[0046] A cylindrical and / or conical portion of an upstream housing portion, downstream housing portion, or both may be an inlet, outlet, or both of the heater. An exhaust stream may flow through the inlet towards and through the outlet. The inlet and / or outlet may be part of the housing. Specifically, the inlet may be part of the upstream housing portion, the outlet may be part of the downstream housing portion, or both. The inlet and / or outlet may be centered or off-center on an end of the upstream and / or downstream housing portions. The inlet and / or outlet may be substantially cylindrical, conical, cuboidal, or otherwise polygonal. The inlet and / or outlet may have a shape substantially reciprocal with a reactor portion adjacent thereto. The inlet may be a same or a different shape and / or size from the outlet. For example, the inlet and outlet may be cylindrical, wi th the inlet having a larger cross-section area than the outlet. As another non-limiting example, the inlet may be cuboidal while the outlet is cylindrical, with the inlet and the outlet having equal cross-section areas.

[0047] The housing may be comprised of one or more materials. One or more materials may be configured to retain the structural rigidity and compression forces of the housing, even in the continuous high operating temperatures it is exposed to. The one or more materials may be able to withstand corrosion from exhaust gases, moisture, salts, the like, or any combination thereof; have a sufficiently high heat resistance; have sufficient durability to handle vibrations and thermalFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOcycling; have a low weight; or a combination thereof. The one or more materials may include one or more metals. One or more metals may include stainless steel, aluminized steel, titanium, nickel, chromium, cast iron, alloys thereof, the like, or any combination thereof. The housing may be formed from sheet metal.

[0048] A housing once assembled may apply an inward compression force onto the one or more mounting mats, conductor plates, heating elements, spacers, or a combination thereof (e.g., interior components). The inward compression force may be applied onto the interior components by the upper and lower housing portions. An inward compression force may be applied onto the upper and lower housing portions by the upstream and downstream housing portions. The spacers in combination with the heating elements, conductor plates, and / or mounting mats may apply an outward counter force. This combination of the inward compression force and the outward counter force may retain the heating elements installed within the heater without employing additional attachment mechanisms. The compression force should be configured such as to not be too high. Too high of pressure may break or damage fibers within the material of the mounting mats. The compression force should be configured such as to not be too low. Too low of pressure may cause loose parts within the heater, lead to vibrating or sliding of components, or a combination thereof. Compression may allow for a lower compression force overall to be applied onto the components of the heater as compared to mechanical fasteners (e.g., bolts). This lower compression force may allow for longer lasting durability of the components. This lower compression may also allow for natural expansion and contraction of some of the components while still being suitably retained within the heater.

[0049] The heater may include one or more electrical connections. One or more electrical connections may provide the electricity that is converted into heat via the heater. One or more electrical connections may be in electrical communication with one or more power sources of a vehicle. One or more electrical connections may include one or more, or even two or more, electrical connections. One or more electrical connections may be referred to as one or more pass through connectors. The one or more electrical connections may be affixed to the housing, one or more conductive elements, or both. The one or more electrical connections may pass from an interior of the housing to an exterior. The one or more electrical connections may be affixed to, in direct contact with, or both one or more conductive elements. One or more conductive elements may include one or more electrical contacts. One or more electrical contacts may be in electrical communication with and / or integral with one or more conductor plates, heating elements, spacers, or a combination thereof. One or more electrical contacts may be located near one or more ends of one or more heating elements. One or more conductor plates may function as the one or moreFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOelectrical contacts. One or more extensions of one or more conductor plates may function as the one or more electrical contacts.

[0050] Exhaust Aftertreatment Apparatus

[0051] The present teachings herein may relate to an exhaust aftertreatment apparatus. The heater of the present teachings may be useful within or as part of the exhaust aftertreatment apparatus.

[0052] Unless otherwise stated, or clearly understood from the context of its use, reference herein to “exhaust stream” includes the stream of exhaust fluid initially emitted as a combustion reaction product from an engine, as well as any resulting fluid reaction products occasioned by an after-treatment step as described herein (e.g., a step of a DOC (diesel oxidation catalyst) reaction, an SCR (selective catalytic reduction) reaction, or other reaction, such as a thermolytic and / or hydrolytic reaction). The use of “untreated” may refer to an exhaust stream that has not yet been mixed with and / or reacted wi th a reactant. The use of “treated” or “mixed” may refer to an exhaust stream that has been mixed with and / or reacted with a reactant.

[0053] The teachings herein relate to an apparatus. The apparatus may be particularly useful in treating an exhaust stream. The apparatus may be referred to as an exhaust aftertreatment apparatus. The exhaust stream may be an exhaust resulting from internal combustion. The internal combustion may be from any engine, such as that of a transportation vehicle. Transportation vehicle may include any vehicle suitable for land, water, and / or air transportation. Transportation vehicles suitable for land may include any size truck, bus, car, all-terrain vehicle, rail vehicle, agricultural equipment, construction equipment, etc. Trucks may include light duty, medium duty, heavy duty7, vocational trucks, etc. The present teachings may also be used in non-vehicular applications. For example, the teachings herein may be applied to stationary generators, pump stations, industrial power generating operations, etc. The internal combustion may be in a diesel engine, gasoline engine, or the like. The apparatus may receive an exhaust stream from a motor. An exhaust line may cany the exhaust stream away from an internal combustion engine and to an inlet of the apparatus. The apparatus may function to reduce particulate matter and pollutants occurring within the exhaust stream, ensure an emitted exhaust stream meets environmental standards, or both. The apparatus may function by reacting with the exhaust stream to collect, remove, reduce, and / or convert particulate matter and pollutants. The apparatus may include a plurality7of components to allow the apparatus to function as recited. The components may include one or more heaters, pipes, tubes, reactor portions, mixers, brackets, diffusers, flow diverters, particle filters, catalysts, injectors, the like, or any combination thereof.

[0054] The apparatus may include one or more heaters. The one or more heaters may be a heater as disclosed herein. The heater may be part of a reactor portion, adjacent to one or more reactor portions, or both. The heater may be located between an upstream reactor portion and aFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOdownstream reactor portion. The heater may be in proximity to, adjacent to. and / or upstream of one or more catalysts, fdters, injectors, or a combination thereof. The heater may function as disclosed herein. For example, the heater may function to heat an exhaust stream flowing therethrough and before flowing into a catalyst which is downstream.

[0055] The apparatus includes one or more reactor portions. The reactor portions may function to house one or more mixers, react (or house a reaction) with an exhaust stream, remove particulates from the exhaust stream, house one or more fdters, house one or more catalysts, receive one or more reactants, or any combination thereof. The one or more reactor portions may have any suitable size and / or shape for housing a mixer, being in communication with a reactant source, reacting with an exhaust stream passing therethrough, removing particulate matter from the exhaust stream, directing the exhaust stream through the same or another reactor portion and / or apparatus, housing one or more other components, or any combination thereof. The one or more reactor portions may be generally cylindrical, cubed, spherical, coned, prismed, the like, or any combination thereof. One or more reactor portions may be tubular. One or more reactor portions may have generally the same shape as, or a different shape from, one or more other reactor portions. One or more reactor portions may have one or more sidewalls (e.g., walls) extending from one end to an opposing end (e.g., a bottom end). One or more reactor portions may include one or more inlets, outlets, or both. An inlet may be opposing an outlet. An inlet of one reactor portion may be adjacent to an outlet of another reactor portion. One or more reactor portions may have a flow axis. The flow- axis may be perpendicular to a radial cross-section of the inlet and / or the outlet, concentric w ith the inlet and / or outlet, coaxial with the longitudinal axis of the reactor portion, or a combination thereof. One or more fdters, catalysts, mixers, evaporation devices, and / or the like may be housed and / or enclosed wrthin one or more reactor portions.

[0056] One or more reactor portions may include one or more upstream reactor portions, intermediate reactor portions, downstream reactor portions, or any combination thereof. Upstream, intermediate, and / or downstream may refer to the location of the reactor portions in relation to one another and the flow of fluid therein (e.g.. exhaust stream). An upstream reactor portion may receive an exhaust stream from an inlet, inlet pipe, or both. An upstream reactor portion may receive an exhaust stream and transmit to either one or more intermediate reactor portions, downstream reactor portions, or both. An intermediate reactor portion may receive an exhaust stream from one or more upstream reactor portions, one or more other intermediate reactor portions, or both. An intermediate reactor portion may transmit an exhaust stream to one or more other intermediate reactor portions, one or more downstream reactor portions, or both. A downstream reactor portion may receive an exhaust stream from one or more upstream reactor portions, intermediate reactor portions, or both. A downstream reactor portion may guide anFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOexhaust stream toward an outlet, outlet pipe, or both. A mixer, catalyst, or both may be part of any reactor portion. A mixer, catalyst, or both may be part of an upstream, downstream, and / or intermediate reactor portion.

[0057] One or more reactor portions may have a generally same or differing length and / or width as one or more other reactor portions. Length may be measured along a flow axis, longitudinal axis, or both of a reactor portion. Width may be measured generally transverse to a flow axis and / or longitudinal axis of a reactor portion. One or more reactor portions may have a width that is substantially continuous. One or more reactor portions may have a width that increases, decreases, or both along a length of the reactor portion.

[0058] One or more reactor portions may be defined by a first end region and / or first end opposite a second end region and / or second end. A first end region may define an inlet of a reactor portion. A second end region may define an outlet of a reactor portion. Flow of an exhaust stream through a reactor portion may be from a first end region, first end, and / or inlet to a second end region, second end, and / or outlet. One or more reactor portions may be in fluid communication with one or more other reactor portions.

[0059] The one or more reactor portions may have a longitudinal axis (e.g., flow axis) extending along their respective length. The longitudinal axis may extend from a first end region of a reactor portion to a second end region of a reactor portion. A first end region may include an end (i. e.. first end, inlet) of a reactor portion. A second end region may include an opposing end (i. e. , second end, outlet) of a reactor portion. The longitudinal axis may be generally concentric or off-center with a cross-sectional area of a reactor portion. For example, a longitudinal axis may be concentric with a diameter of a reactor portion. The longitudinal axis of one or more reactor portions may be generally parallel with, perpendicular to, or at any angle therebetween relative to the longitudinal axis of one or more other reactor portions. ‘'Generally” may mean within about 5°, within about 10°, or even within about 20° from the values stated. The longitudinal axis of one or more reactor portions may be concentric with, aligned with, un-centered from, off-set from, or any combination thereof relative to one or more other longitudinal axes of one or more other reactor portions. Longitudinal axes that are generally parallel with and off-set from one another may allow for the reactor portions to be consolidated and placed adjacent to one another (e.g., a box-style exhaust system). Longitudinal axes that are generally parallel with and substantially aligned with one another may allow for reactor portions to form an "in-line” exhaust system. A longitudinal axis may define an axis of a Cartesian coordinate system. The longitudinal axis may define an x-axis of each reactor portion. Generally transverse to the x-axis and / or longitudinal axis may be ay-axis and / or a z-axis. The y-axis, z-axis, or both may be located at about a mid-length of a reactor portion. The differing axes may be useful in relating one or more components of the apparatusFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOwith one another, an exhaust stream passing through the apparatus, dimensions of one or more components, and the like. A longitudinal axis may be referred to as a flow axis (e.g., with reference to flow through a reactor portion of an exhaust stream).

[0060] A flow axis may indicate the direction of flow of an exhaust stream relative to a longitudinal axis, along a length of a reactor portion, along one or more passages of a mixer, or any combination thereof. A flow axis may extend from one end region to an opposing second end region. The flow axis of one or more components may flow in a same direction, transverse direction, and / or opposing direction as the flow axis of one or more other portions. One or more reactor portions may have a single flow axis or a plurality of flow axes. A reactor portion housing one or more mixers, diffusers, and / or flow diverters may include a plurality of flow axes that change the direction of flow therein. A plurality of flow axes may include a first flow axis, a second flow axis, a third flow axis, the like, or any combination thereof. The plurality' of flow axes may be concentric or off-center with one another.

[0061] The apparatus may’ include one or more catalysts. The one or more catalysts may be configured to initiate and / or perform one or more reactions. The one or more reactions may function to reduce toxic gases, toxic pollutants, greenhouse gases, or a combination thereof. Greenhouse gases may include carbon dioxide, methane, nitrous oxide, fluorinated gases, or any combination thereof. The one or more reactions may function to oxidize hydrocarbon, oxidize carbon monoxide, reduce hydrogen compounds, reduce nitrogen oxides, reduce sulfur oxides, oxidize methane, or any combination thereof. Exemplary catalysts may' include a diesel oxidation catalyst (DOC), methane oxidation catalyst (MOC), selective catalytic reactor (SCR), ammonia slip catalyst (ACR), the like, or any combination thereof. The one or more catalysts may be located in one or more reactor portions, one or more flow pipes, or a combination thereof. The one or more catalysts may be located within the same and / or a different reactor portion as one or more other catalysts and filters. For example, an upstream reactor portion may include a diesel oxidation catalyst and a diesel particulate filter. For example, a downstream reactor portion may include both a selective catalyst reactor and an ammonia slip catalyst. One or more catalysts may be combined with a carrier, supported on a support structure, or both. One or more filters may function as a carrier and / or support structure for a catalyst. A plurality' of catalysts may be placed in any sequence within the apparatus. As one example, the diesel oxidation catalyst may be located upstream of the selective catalytic reactor and ammonia slip catalyst. As another example, the selective catalytic reactor may be located upstream of the diesel oxidation catalyst.

[0062] The one or more catalysts may include an oxidation catalyst (e.g., diesel oxidation catalyst, DOC). The oxidation catalyst may function to reduce and / or oxidize carbon monoxide and / or hydrocarbons within the exhaust stream, convert carbon monoxide and / or hydrocarbons intoFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOcarbon dioxide and / or water or both. The oxidation catalyst may be located within one or more reactor portions, filters, or both. For example, an oxidation catalyst may be integrated into a particulate filter. The oxidation catalyst may be located within one or more of the upstream, intermediate, and / or downstream reactor portions. The catalyst may react with the high temperature of an exhaust stream as the stream passes through a reactor portion and contacts the catalyst. Upon contact with the hot exhaust stream, the catalyst may convert the carbon monoxide and / or hydrocarbons. The oxidation catalyst may be any catalyst suitable for functioning as recited. Suitable catalysts may include palladium, platinum, rhodium, the like, or any combination thereof

[0063] The one or more catalysts may include a selective catalytic reactor. The selective catalytic reactor may function to reduce nitrogen oxides (NOx) present within the exhaust stream, convert nitrogen oxides into nitrogen and / or water, or a combination of both. The selective catalytic reactor may be located within one or more reactor portions, filters, or both. The selective catalytic reactor portion may be located downstream of an introduction point of one or more reactants into the apparatus and / or exhaust stream. The selective catalytic reactor may be located within one or more of the upstream, intermediate, and / or downstream reactor portions. The selective catalytic reactor may react with ammonia present within the exhaust stream to reduce and / or convert the nitrogen oxides. The selective catalytic reactor may be located downstream of one or more fluid delivery' devices which introduce one or more reactants, one or more mixers, an upstream reactor portion, one or more intermediate reactor portions; upstream and / or within a downstream reactor portion; or any combination thereof. A selective catalytic reactor may be any catalyst suitable for functioning as recited. Exemplary' selective catalytic reactors may include one or more ceramic materials, one or more metals, one or more minerals, or a combination thereof. One or more metals may include vanadium, molybdenum, tungsten, precious metals, or any combination thereof. One or more minerals may include zeolites. The selective catalytic reactor may be located in a same or different reactor portion as an ammonia slip catalyst. The selective catalytic reactor may cooperate with an ammonia slip catalyst.

[0064] The one or more catalysts may include an ammonia slip catalyst. An ammonia slip catalyst may be useful in eliminate trace amounts of ammonia remaining within an exhaust stream. The ammonia slip catalyst may oxidize some of the ammonia present within an exhaust stream. The ammonia may be oxidized into nitrogen gas and water. The ammonia may be present after the exhaust stream mixes with one or more reactants, reacts within a selective catalytic reactor, or both. The ammonia slip catalyst may be located within one or more reactor portions, fdters, or both. The ammonia slip catalyst may be located within one or more the upstream, intermediate, and / or downstream reactor portions. The ammonia slip catalyst may be located downstream of one or more fluid delivery devices which introduce one or more reactants, one or more mixers, anFiled via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOupstream reactor portion, one or more intermediate reactor portions; upstream and / or within a downstream reactor portion; or any combination thereof. The ammonia slip catalyst may be located in a same or different reactor portion as a selective catalytic reactor. The ammonia slip catalyst may be located close to an outgoing end of a reactor portion than an incoming end. For example, the ammonia slip catalyst may be located near an outgoing end of a reactor portion having a selective catalytic reactor therein. An ammonia slip catalyst may be any catalyst able to function as recited. Exemplary ammonia slip catalysts may include one or more metals. The one or more metals may include platinum, palladium, or a mixture thereof. The ammonia slip catalyst may react with remnants of ammonia resulting from one or more reactants.

[0065] The apparatus may include one or more fluid delivery devices (e.g., valve, injector). The one or more fluid delivery devices may inject and / or control passage of a reactant (e.g., reactant) into the apparatus, one or more reactor portions, and / or one or more mixers; into contact with the exhaust stream; control flow of a reactant toward a mixer; or any combination thereof. The one or more fluid delivery devices may be any suitable device for releasing and controlling the passage of a reactant into the apparatus. The one or more fluid delivery devices may include a single jet and / or nozzle or a plurality of jets and / or nozzles for releasing a reactant. The one or more fluid delivery devices may be located in the apparatus, upstream of a catalyst, upstream and / or downstream of a filter, upstream and / or downstream of a heater, or a combination thereof. The one or more fluid delivery devices may inject a reactant into the apparatus such that the reactant flows generally parallel with, perpendicular to, or at any angle therebetween relative to a flow axis of a reactor portion, the direction of flow of the exhaust stream within a reactor portion and / or mixer, or a combination thereof.

[0066] The apparatus may include one or more filters. The one or more filters may function to collect and / or remove particulate matter from an exhaust stream, break apart larger sizes of particulate matter into smaller particles, cany7one or more catalysts, or any combination thereof. Particulate matter may include soot residing within an exhaust stream of an internal combustion engine (e.g., diesel engine). The one or more filters may collect particulate matter on one or more surfaces of the filter (e.g., surfaces created by pores). Accumulated particulate matter may be removed through active, passive, and / or forced regeneration. The one or more filters may bum off accumulated particulate matter. Burning off of particulate matter may occur through a catalyst or a burner. One or more filters may include one or more diesel particulate filters (“DPF”). Exemplary- filters can be found in US Patent Nos.: 8336301, 8763375, 9074522.9188039. and 9334785. which are incorporated herein by reference in their entirety- for all purposes. Suitable filters may include cordierite w all flow- filters, silicon carbide wall flow filters, ceramic fiber filters, metal fiber flow-through filters, partial filters, the like, or any combination thereof. Suitable filters may include oneFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOor more diesel and / or petrol filters. The one or more filters may be located in, adjacent to, proximate to, and / or in fluid communication with one or more reactor portions. For example, a filter may be located in an upstream reactor portion and / or a downstream reactor portion. The one or more filters may be located along part of or all of a length of a reactor portion. The one or more filters may carry a catalyst (e.g.. coated with a catalyst) or be free of a catalyst. The catalyst may allow a filter to also react with the exhaust stream in addition to removing particulate matter. For example, a particulate filter may also be and / or carry thereon an oxidation catalyst.

[0067] Illustrative Examples

[0068] FIG. 1 illustrates an apparatus 10. The apparatus 10 is an exhaust aftertreatment apparatus 12. The apparatus 10 is formed as an “in-line” exhaust system. The apparatus 10 includes a one or more reactor portions 14. A reactor portion 14 may include an upstream reactor portion 16 and a downstream reactor portion 18. A downstream reactor portion 18 may include a catalyst 20 (e.g., located inside). Betw een the reactor portions 14 is a heater 100. The heater 100 is formed as an electric exhaust heater 102.

[0069] FIGS. 2 and 3 are close-up views of the heater 100. The heater 100 is formed as an electric exhaust heater 102.

[0070] FIGS. 4 and 5 are front and rear perspective views of a heater 100. The heater 100 is an electric exhaust heater 102. The heater 100 includes a housing 104. The housing 104 includes a central region 103. The central region 103 may also be referred to as a cuboid region. The housing 104 is formed by an upper housing portion 104a mating with a low er housing portion 104b. The upper housing portion 104a and lower housing portion 104b may mate to form the central region 103. The housing 104 forms a first shape toward its interior and changes shape toward the exterior. In this example, the housing 104 has a substantially cuboidal shape which then tapers to opposing cylindrical shapes. The exterior shape at either end may be reciprocal with the shape of an adjacent reactor portion 14 (not shown). The housing 104 includes an upstream housing portion 104c opposite of a downstream housing portion 104d. The upstream and dow nstream housing portions 104c. d form the exterior ends of the housing 104. The housing 104 includes an inlet 105a and an outlet 105b. The inlet 105a is formed in the upstream housing portion 104c. The outlet 105b is formed in the downstream housing portion 104d. The housing 104 is hollow; The exhaust stream flows through the housing 104, through the inlet 105a toward and through the outlet 105b.

[0071] Within the heater 100 are a plurality of heating elements 106. The heating elements 106 are arranged as one or more arrays within the housing 104. Each heating element 106 is formed as an undulating while also having a wavy surface. In other words, the heating element has an undulating large-scale shape (e.g., repeating bends) while also having surface waviness on the surface profde.Filed via USPTO.GOV on January 23. 2026Docket No. 2035.013WO

[0072] The heater 100 includes connectors 108. The connectors 108 are or include pass through connectors 110. The connectors 108 are in electrical communication (e.g., contact) with the conductor plates 12 (not shown), such as upper conductor plates 112a (not shown).

[0073] FIG. 6 is a cross-section view of a heater 100. FIG. 7 is a front view of a heater 100. The heater 100 is an electric exhaust heater 102. The heater 100 includes a housing 104.

[0074] Inside of the housing 104 are conductor plates 112. The conductor plates 112 include one or more upper conductor plates 112a and one or more lower conductor plates 112b. For example, a pair of upper conductor plates 112a and a single low er conductor plate 112b. The upper conductor plate(s) 112ais / are opposite and distanced from the lower conductor plate 112b.

[0075] Inside of the housing 104 are a plurality of heating elements 106. Each heating element 106 spans the distance between the conductor plates 112, specifically from the lower conductor plate 112b to the upper conductor plate 112a. Each heating element 106 is formed with an overall undulating shape while also having a wavy texture.

[0076] Located between each undulation of a heating element 106 is a spacer 114. Each spacer 114 has a substantial disc, annular, or cylindrical shape.

[0077] Sandwiching the conductor plates 112 is a pair of mounting mats 116. The mounting mats include an upper mounting mat 116a distanced and opposite from a lower mounting mat 116b.

[0078] The heating elements 106 and spacers 114 are compression fit between the mounting mats 116. Aside from the compression, no other attachment mechanism (e.g., brazing, w elding, threaded fastener) retains the heating elements 106 and spacers 114 in place. The compression force is applied to the mounting mats 116 via the housing 104.

[0079] FIG. 8 shows a partially exploded view of the heater 100. The heater 100 includes a housing 104. The housing 104 includes an upper housing portion 104a which mates with a lower housing portion 104b. The upper housing portion 104a and lower housing portion 104b may form a central region 103, which may be a cuboid region. The housing 104 includes an upstream housing portion 104c opposite of a downstream housing portion 104d. The upstream and downstream housing portions 104c, d may sandwich the central region 103 therebetween. The inward facing rims 107a of the upstream and downstream housing portions 104c, d may go about the outward facing rims of the upper and lower housing portion 104a, b such as to retain the housing portions 104a-d together.

[0080] FIG. 9 illustrates some of the interior components of the heater 100 (partially shown). The heater 100 includes a plurality of heating elements 106. The heater 100 includes a pair of upper conductor plates 112a. Each conductor plate 112, 112a is generally T-shaped. Each upper conductor plate 112a spans across a plurality of heating elements 106. As shown, each upper conductor plate 112a spans across and is connected to two heating elements 106. Each upperFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WOconductor plate 112a includes an extension 113. The extension is configured to be in electrical contact with one or more electrical connectors 108 (not shown). The extension includes an opening 115. The opening 115 may receive and be affixed to a pass through connector 110 (not show n).

[0081] FIG. 10 illustrates the heating elements 106 separated from their associated stack of spacers 114. The spacers 114 are in an alternating stacked arrangement with the undulations of the heating element 106. The spacers 114 have an annular disc shape.

[0082] Reference Number List

[0083] 10 Apparatus

[0084] 12 Exhaust aftertreatment apparatus

[0085] 14 Reactor portion

[0086] 16 Upstream reactor portion

[0087] 18 Downstream reactor portion

[0088] 20 Catalyst

[0089] 100 Heater

[0090] 102 Electric exhaust heater

[0091] 103 Central region of housing

[0092] 104 Housing

[0093] 104a Upper housing portion

[0094] 104b Lower housing portion

[0095] 104c Upstream housing portion

[0096] 104d Downstream housing portion

[0097] 105a Inlet

[0098] 105b Outlet

[0099] 106 Heating element

[0100] 107a Inward facing rim

[0101] 107b Outward facing rim

[0102] 108 Connector

[0103] 110 Pass through connector

[0104] 112 Conductor Plates

[0105] 112a Upper conductor plate

[0106] 112b Low er conductor plate

[0107] 113 Extension

[0108] 114 Spacer

[0109] 115 Opening

[0110] 116 Mounting matFiled via USPTO.GOV on January 23. 2026Docket No. 2035.013WO

[0111] 116a Upper mounting mat

[0112] 116b Lower mounting mat

[0113] Any numerical values recited in the above application include all values from the lower value to the upper value in increments of one unit, provided that there is a separation of at least 2 units between any lower value and any higher value. These are only examples of what is specifically intended, and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints.

[0114] The terms “generally7’ or “substantially” to describe angular measurements may mean about + / - 10° or less, about + / - 5° or less, or even about + / - 1° or less. The terms “generally” or “substantially” to describe angular measurements may mean about + / - 0.01° or greater, about + / -0.1° or greater, or even about + / - 0.5° or greater. The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 10% or less, about + / -5% or less, or even about + / - 1% or less. The terms “generally” or “substantially” to describe linear measurements, percentages, or ratios may mean about + / - 0.01% or greater, about + / - 0.1% or greater, or even about + / - 0.5% or greater.

[0115] The term “consisting essentially of’ to describe a combination shall include the elements, ingredients, components, or steps identified, and such other elements, ingredients, components, or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components, or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components, or steps.

[0116] Plural elements, ingredients, components, or steps can be provided by a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step might be divided into separate plural elements, ingredients, components, or steps. The disclosure of “a” or “one” to describe an element, ingredient, component, or step is not intended to foreclose additional elements, ingredients, components, or steps.

Claims

Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOCLAIMSWhat is claimed is:Claim 1. A heater for an exhaust aftertreatment apparatus, the heater comprising:a) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough;andb) one or more heating elements within the housing and retained in place by compression.Claim 2. The heater of Claim 1, wherein the housing has a substantially cuboidal region between the inlet and the outlet; andwherein the substantially cuboidal region houses the one or more heating elements.Claim 3. The heater of any of the preceding claims, wherein the one or more heating elements have an undulating, corrugated, and / or rib-shaped profile.Claim 4. The heater of Claim 3, wherein the undulating, corrugated, and / or rib-shaped profile includes one or more U-shaped bends.Claim 5. The heater of any Claim 3 or 4, wherein the one or more heating elements has a wavy pattern along a length of the heating element; andwherein the wavy pattern is in addition to an undulating corrugated, and / or rib-shaped profile of the one or more heating elements.Claim 6. The heater of any of the preceding claims, wherein the one or more heating elements comprises one or more materials that are electrically conductive, heat conductive, or both.Claim 7. The heater of Claim 6, wherein the one or more materials are one or more metals.Claim 8. The heater of Claim 7, wherein the one or more metals include nickel, chromium, copper, aluminum, stainless steel, the like, or a combination thereofClaim 9. The heater of Claim 8, wherein the one or more metals include nichrome.Filed via USPTO.GOV on January 23. 2026Docket No. 2035.013WOClaim 10. The heater of any of the preceding claims, wherein the one or more heating elements are arranged in an array, a staggered pattern, or both across a width, depth, and / or height of the heater.Claim 11. The heater of any of the preceding claims, wherein the one or more heating elements include a plurality of heating elements.Claim 12. The heater of any of the preceding claims, wherein the one or more heating elements include 1 or more to 10 or fewer heating elements.Claim 13. The heater of any of the preceding claims, wherein the heater includes one or more spacers configured to maintain the length, height, and / or shape of each heating element, apply a counter force to a compression force, or both; andwherein the compression force generates the compression that retains the one or more heating elements within the housing.Claim 14. The heater of Claim 13, wherein the one or more spacers include a plurality of spacers.Claim 15. The heater of Claim 13 or 14, wherein each undulation of a heating element of the one or more heating elements includes a spacer therein.Claim 16. The heater of Claim 15, wherein the one or more plurality of spacers are altematingly arranged with one or more undulations of the one or more heating elements such as to form a stack.Claim 17. The heater of any of claims 13 to 16, wherein the one or more spacers have a shape which is substantially disc shaped, annular, cylindrical, or a combination thereof.Claim 18. The heat of any of Claims 14 to 17, w herein the one or more spacers comprise one or more materials which are electrically insulating, thermally insulating, or both.Claim 19. The heater of any of Claims 13 to 18, wherein the one or more spacers are comprised of one or more materials including ceramic, glass, carbon, minerals, composites thereof, the like, or any combination.Filed via USPTO.GOV on January 23. 2026Docket No. 2035.013WOClaim 20. The heater of Claim 18, wherein the one or more spacers are comprised of ceramic.Claim 21. The heater of any of the preceding claims, wherein the heater includes one or more conductor plates between the housing and the one or more heating elements.Claim 22. The heater of Claim 21, wherein the conductor plates include one or more upper conductor plates and one or more lower conductor plates.Claim 23. The heater of Claim 22, wherein the one or more upper conductor plates are distanced and opposite from the one or more lower conductor plates.Claim 24. The heater of Claim 23, wherein the one or more heating elements span the distance between the one or more upper conductor plates and the one or more lower conductor plates.Claim 25. The heater of any of the preceding claims, wherein the heater includes one or more electrical contacts for transferring electricity from one or more pass through connectors to the one or more conductor plates, the one or more heating elements, or both.Claim 26. The heater of Claim 25, wherein the one or more electrical contacts are located between the one or more conductor plates and one or more heating elements.Claim 27. The heater of any of the preceding claims, wherein the housing includes one or more mounting mats, threaded fasteners, and / or biasing devices that apply compression to the one or more heating elements to retain the one or more heating elements within the housing.Claim 28. The heater of Claim 27. wherein the one or more mounting mats includes a plurality of mounting mats; andwherein the plurality of mounting mats includes one or more upper mounting mats and one or more lower mounting mats.Claim 29. The heater of Claim 28, wherein the one or more upper mounting mats are distanced from and opposite the one or more low er mounting mats.Filed via USPTO.GOV on Januaiy 23. 2026Docket No. 2035.013WOClaim 30. The heater of Claim 28 or 29. wherein the one or more heating elements are located between the one or more upper mounting mats and the one or more lower mounting mats.Claim 31. The heater of any of Claims 27 to 30, wherein the one or more mounting mats are affixed to the housing.Claim 32. The heater of any of Claims 27 to 30, wherein between the one or more mounting mats and the one or more heating elements are one or more conductor plates.Claim 33. The heater of any of Claims 27 to 32, wherein the one or more mounting mats apply the compressive force onto the one or more heating elements, spacers, conductor plates, or a combination thereof to retain the one or more heating elements, spacers, conductor plates, or a combination thereof w ithin the housing.Claim 34. The heater of any of Claims 27 to 33, wherein the one or more mounting mats comprise one or more materials which are electrically insulating, thermally insulating, or both.Claim 35. The heater of any of Claims 27 to 34, wherein the one or more mounting mats comprised one or more materials which include ceramic, glass, carbon, minerals, composites thereof, the like, or any combination.Claim 36. The heater of Claim 35, wherein the one or more materials of the one or more mounting mats is a fiber reinforced material.Claim 37. The heater of Claim 36, wherein one or more fibers in the fiber reinforced material includes glass, mineral, carbon, silicone, metal (e.g., aluminum), zirconia, basalt, silica, the like, or a combination thereof.Claim 38. The heater of any of the preceding claims, wherein the one or more heating elements include a plurality of heating elements arranged across a width of an interior of the housing;wherein the one or more heating elements have an undulating profile with a wavy texture across a length and / or height of the one or more heating elements;w herein the heater includes a plurality of spacers which are altematingly arranged with the undulations of the one or more heating elements to form a stack;Filed via USPTO.GOV on January 23. 2026Docket No. 2035.013WOwherein the heater includes one or more upper conductor plates arranged at an upper end of the one or more heating elements and one or more lower conductor plates arranged at a lower end of the one or more heating elements; andwherein the heater includes one or more upper mounting mats between the housing and the one or more upper conductor plates and one or more lower mounting mats between the housing and the one or more lower conductor plates.Claim 39. The heater of any of the preceding claims, wherein the heater is part of the exhaust aftertreatment apparatus.Claim 40. The heater of Claim 39, wherein the heater is upstream of a catalyst, injector, or both.Claim 41. The heater of any of the preceding claims, wherein the heater is an electric exhaust heater.Claim 42. The heater of any of the preceding claims, wherein the housing includes an upper housing portion mated to a lower housing portion to form a central region which houses the one or more heating elements;wherein the housing includes an upstream housing portion which includes the inlet and is affixed to both the upper housing portion and the lower housing portion; andwherein the housing includes a downstream housing portion opposite the upstream housing portion and which includes the outlet affixed to both the upper housing portion and the lower housing portion.Claim 43. The heater of Claim 42, wherein an inward facing rim of the upstream housing portion and the downstream housing portion receives and is affixed to an inward facing rim of the central region of the housing.Claim 44. A heater for an exhaust aftertreatment apparatus, the heater comprising:a) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough;andb) one or more heating elements within the housing and retained in place by compression; wherein the one or more heating elements include a plurality of heating elements arranged across a width of an interior of the housing;Filed via USPTO.GOV on January 23. 2026Docket No. 2035.013WOwherein the one or more heating elements have an undulating profile with a wavy texture across a length and / or height of the one or more heating elements;wherein the heater includes a plurality of spacers which are altematingly arranged with the undulations of the one or more heating elements to form a stack;wherein the heater includes one or more upper conductor plates arranged at an upper end of the one or more heating elements and one or more lower conductor plates arranged at a lower end of the one or more heating elements; andwherein the heater includes one or more upper mounting mats between the housing and the one or more upper conductor plates and one or more lower mounting mats between the housing and the one or more lower conductor plates.Claim 45. The heater of Claim 44 comprising any of the features of any of Claims 1 to 43.Claim 46. An exhaust aftertreatment apparatus comprising:a) a heater including:i) a housing having an inlet and outlet for allowing an exhaust stream to pass therethrough;andii) one or more heating elements within the housing and retained in place by compression;andb) a catalyst downstream and adjacent to the heater.Claim 47. The exhaust aftertreatment apparatus of Claim 46, wherein the exhaust aftertreatment apparatus comprises any of the features of any of Claims 1 to 45.

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