EP4649229A1

EP4649229A1 - Catalyst substrate heaters having improved heating profiles

Info

Publication number: EP4649229A1
Application number: EP24704660.0A
Authority: EP
Inventors: Thomas Adam Collins; David Robert HEINE; Egor KUZNETSOV; Mitchell Eugene SMITH
Original assignee: Corning Inc
Current assignee: Corning Inc
Priority date: 2023-01-11
Filing date: 2024-01-08
Publication date: 2025-11-19
Also published as: CN120604022A; WO2024151496A1

Abstract

The present disclosure is directed to resistive heater bodies having a honeycomb structure and one or more current directing features, systems incorporating such resistive heater bodies. The honeycomb heater bodies and systems of the present disclosure find particular application in reducing cold-start emissions in gasoline- and diesel-powered engines. More specifically, the resistive heater bodies of the present disclosure provide current directing features enabling improved heating performance of downstream catalyst-containing substrates.

Description

CATALYST SUBSTRATE HEATERS HAVING IMPROVED HEATING PROFILES

Cross Reference to Related Application

[0001] This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Serial No. 63/438308, filed on January 11, 2023, the content of which is relied upon and incorporated herein by reference in its entirety.

Field of the Disclosure

[0002] The present disclosure relates generally to resistive heater bodies for use in fluid aftertreatment systems, and more specifically, to resistive heater bodies having one or more current directing features.

Background

[0003] In modem gasoline- and diesel-powered engines, an exhaust aftertreatment system may be used to reduce the emissions produced during operation of the engines, including but not limited to particulate matter, volatile organic compounds, nitrogen oxides, carbon monoxide, carbon dioxide, and sulfur dioxide. In some aftertreatment systems, a catalystcontaining substrate may be used to trap one or more of these undesirable emissions. However, cold start emissions (i.e., the emissions produced during the first 20 to 60 seconds after ignition) continue to represent the most toxic segment of the engine operating cycle. During this period, the catalyst-containing substrates do not reach full efficiency until the engine exhaust heats the catalyst up to the temperature at which catalytic reactions are initiated.

Summary of the Disclosure

[0004] According to one embodiment of the present disclosure, a resistive heater body is provided. The resistive heater substrate comprises: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending into the resistive heater body from an outer periphery of the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots create a serpentine pattern for the plurality of cell channels from a first side of the resistive heater body to a second side of the resistive heater body; and one or more current directing features, each current directing feature being proximal to a terminal end of at least one of the plurality of slots, wherein each current directing feature comprises: (i) a first linear portion extending in a first direction perpendicular to a slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) a middle portion having one or more modified cell channels that connect the first and second linear portions.

[0005] In an aspect, the plurality of cell channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0006] In an aspect, the slots extend axially from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0007] In an aspect, the first and second linear portions of the one or more current directing features comprise thickened cell walls that have a thickness greater than a thickness of the intersecting cell walls.

[0008] In an aspect, the middle portion of the one or more current directing features comprise one or more filleted and/or chamfered cell walls.

[0009] In an aspect, the first and second linear portions of the one or more current directing features comprise thickened cell walls that extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0010] In an aspect, the one or more modified cell walls of the middle portion of the one or more current directing features extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0011] In an aspect, each of the plurality of slots have a width equal to one cell channel.

[0012] In an aspect, the middle portion of each of the one or more current directing features is centered one cell channel away from the terminal end of at least one of the plurality of slots. [0013] In an aspect, the terminal end of each of the plurality of slots is spaced from an outer peripheral region of the resistive heater body by at least five cell channels. [0014] In an aspect, each terminal end of one or more slots of the plurality of slots is spaced from an outer peripheral region of the resistive heater body by at most two cell channels.

[0015] In an aspect, one or more slots of the plurality of slots extend into the resistive heater body from the outer periphery of the resistive heater body for a first length in a first direction, and at least a second length in a second direction.

[0016] According to another embodiment of the present disclosure, a resistive heater body is provided that comprises: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending into the resistive heater body from an outer periphery of the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots create a serpentine pattern for the plurality of cell channels from a first side of the resistive heater body to a second side of the resistive heater body; one or more current directing features, each current directing feature being proximal to a terminal end of at least one of the plurality of slots, wherein each current directing feature comprises a continuous length of modified cell walls corresponding to an array of partially-filled cell channels; wherein one or more slots of the plurality of slots have a corresponding terminal end that is spaced from an outer peripheral region of the resistive heater body by at most two cell channels.

[0017] In an aspect, the plurality of cell channels extend in an axial direction through the resistive heater body from a first end face of the resistive heater body to a second end face of the resistive heater body.

[0018] In an aspect, the slots extend axially from a first end face of the resistive heater body to a second end face of the resistive heater body

[0019] In an aspect, at least a portion of one or more of the current directing features follows a contour of the outer peripheral region.

[0020] In an aspect, the one or more current directing features further comprises one or more completely-filled cell channels along the continuous length of the current directing feature.

[0021] In an aspect, the resistive heater body further comprises one or more regions of completely-filled cell channels, each region being adjacent to the outer peripheral region of the resistive heater body, and each region being spaced apart from one or more current directing features by at least one cell channel.

[0022] In an aspect, one or more slots of the plurality of slots extend into the resistive heater body from the outer periphery of the resistive heater body for a first length in a first direction, and at least a second length in a second direction. According to another embodiment of the present disclosure, a fluid treatment system is provided. The fluid treatment system comprises: a catalyst-containing substrate in fluid communication with a resistive heater body, the resistive heater body positioned upstream from the catalyst-containing substrate; wherein the resistive heater body comprises: a plurality of cell channels formed by intersecting cell walls, wherein the intersecting cell walls are formed from a heater body composition comprising an electrically conductive material; a plurality of slots extending into the resistive heater body from an outer periphery of the resistive heater body in alternating directions along a dimension of the resistive heater body, wherein the plurality of slots create a serpentine pattern for the plurality of cell channels from a first side of the resistive heater body to a second side of the resistive heater body; and one or more current directing features, each current directing feature being proximal to a terminal end of at least one of the plurality of slots, wherein each current directing feature comprises: (i) a first linear portion extending in a first direction perpendicular to a slot direction; (ii) a second linear portion extending in a second direction perpendicular to the slot direction; and (iii) a middle portion having one or more modified cell channels that connect the first and second linear portions.

[0023] These and other aspects of the various embodiments will be apparent from and elucidated with reference to the embodiments described hereinafter.

Brief Description of the Drawings

[0024] In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the various embodiments.

[0025] FIG. 1 is a diagram illustrating a resistive heater body according to aspects of the present disclosure. [0026] FIG. 2A is a diagram illustrating certain modified cell channel arrangements according to aspects of the present disclosure.

[0027] FIG. 2B is a diagram illustrating further modified cell channel arrangements according to aspects of the present disclosure.

[0028] FIG. 3 is a diagram illustrating a first current directing features at a terminal end of a slot of a resistive heater body according to aspects of the present disclosure.

[0029] FIG. 4 is a diagram illustrating a second current directing features at a terminal end of a slot of a resistive heater body according to aspects of the present disclosure.

[0030] FIG. 5 is a diagram illustrating a third current directing features at a terminal end of a slot of a resistive heater body according to aspects of the present disclosure.

[0031] FIG. 6 is a diagram illustrating the heating performance in a resistive heater having a comparative current directing feature according to aspects of the present disclosure.

[0032] FIG. 7 is a diagram illustrating the changes in heating performance in a resistive heater body having a first current directing feature relative to the comparative current directing feature according to aspects of the present disclosure.

[0033] FIG. 8 is a diagram illustrating the changes in heating performance in a resistive heater body having a second current directing feature relative to the comparative current directing feature according to aspects of the present disclosure.

[0034] FIG. 9 is a diagram illustrating the changes in heating performance in a resistive heater body having a third current directing feature relative to the comparative current directing feature according to aspects of the present disclosure.

[0035] FIG. 10A is a diagram illustrating a first combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0036] FIG. 10B is a diagram illustrating the heating performance in a resistive heater body having a first combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0037] FIG. 11 A is a diagram illustrating a second combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0038] FIG. 1 IB is a diagram illustrating the heating performance in a resistive heater body having a second combination of a current directing feature and a slot design according to aspects of the present disclosure. [0039] FIG. 12A is a diagram illustrating a third combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0040] FIG. 12B is a diagram illustrating the heating performance in a resistive heater body having a third combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0041] FIG. 13A is a diagram illustrating a fourth combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0042] FIG. 13B is a diagram illustrating the heating performance in a resistive heater body having a fourth combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0043] FIG. 14A is a diagram illustrating a fifth combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0044] FIG. 14B is a diagram illustrating the heating performance in a resistive heater body having a fifth combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0045] FIG. 15A is a diagram illustrating a sixth combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0046] FIG. 15B is a diagram illustrating the heating performance in a resistive heater body having a sixth combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0047] FIG. 16A is a diagram illustrating a seventh combination of a current directing feature and a slot design of a resistive heater body according to aspects of the present disclosure.

[0048] FIG. 16B is a diagram illustrating the heating performance in a resistive heater body having a seventh combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0049] FIG. 17 is a cross-sectional side view illustration of a fluid treatment system comprising a catalyst substrate and a resistive heater assembly according to aspects of the present disclosure. [0050] FIG. 18A is a diagram illustrating the heating performance of a honeycomb substrate located downstream from a resistive heater body having a baseline fdlet pattern according to aspects of the present disclosure.

[0051] FIG. 18B is a diagram illustrating the heating performance of a honeycomb substrate located downstream from a resistive heater body having a fourth combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0052] FIG. 18C is a diagram illustrating the heating performance of a honeycomb substrate located downstream from a resistive heater body having a fifth combination of a current directing feature and a slot design according to aspects of the present disclosure.

[0053] FIG. 18D is a diagram illustrating the heating performance of a honeycomb substrate located downstream from a resistive heater body having a sixth combination of a current directing feature and a slot design according to aspects of the present disclosure.

Detailed Description of Embodiments

[0054] One approach to reducing undesirable emissions in gasoline- and die sei -powered engines is the use of substrates and/or filters in an exhaust aftertreatment system. For example, catalyst-containing substrates may be configured in a fluid treatment system to receive exhaust from the engine prior to releasing the exhaust into the environment, whereby certain undesirable components of the exhaust are captured in a chemical reaction within the catalystcontaining substrate. However, even in fluid treatment systems having a catalyst-containing substrate, cold start emissions contribute a significant amount of undesirable emissions during a typical engine operating cycle.

[0055] To address the issue of cold start emissions, the present disclosure is directed to resistive heater bodies having one or more current directing features and find particular application in fluid treatment systems to reduce the light-off time of a catalyst in a catalystcontaining substrate of the fluid treatment system. More specifically, resistive heater bodies must allow electrical currents to flow through the heater body in such a way so as to enable effective heating of a proximate fluid flow (e.g., exhaust gas, etc.). However, depending on the flow of the electrical current, conventional resistive heater designs can lead to cold spots where the resistive heater body does not heat as effectively as other areas of the resistive heater body. Thus, the present disclosure is directed to heater bodies comprising one or more current directing features that address these and other drawbacks.

[0056] Turning to FIG. 1, a resistive heater body 100 for use in a fluid treatment system is shown according to various aspects of the present disclosure. As shown, the resistive heater body 100 comprises a plurality of cell channels 102 formed by an array of intersecting cell walls 104, 104'. The resistive heater body 100 can comprise a skin 128 providing additional structural support and formed at an outer periphery 118 of the resistive heater body 100. The plurality of cell channels 102 can be parallel to one another and extend in an axial direction through the resistive heater body 100 between opposite end faces of the body 100 (e.g., from a first end face to a second end face of the resistive heater body 100).

[0057] In the example of FIG. 1, the cell channels 102 generally have a rectangular cross- sectional shape. However, in embodiments, one or more of the cell channels 102 can have other regular or irregular cross-sectional shapes, including but not limited to, triangular, heptagonal, hexagonal, octagonal, trapezoidal, diamond, circular, ellipsoidal, other polygonal shapes, and/or combinations thereof. In particular embodiments, the comers of the cell channels 102 can be radiused or filleted as discussed in more detail below. In embodiments, the peripheral shape of the resistive heater body 100 can be circular, as shown in FIG. 1. However, the peripheral shape of the resistive heater body 100 can alternatively be rectangular, triangular, heptagonal, hexagonal, octagonal, trapezoidal, diamond, circular, ellipsoidal, or another polygonal shape. In embodiments, these arrangements of cell channels 102 and cell walls 104, 104' may be referred to as a honeycomb substrate or a honeycomb body.

[0058] In some embodiments, the intersecting cell walls 104, 104' can be formed from a batch mixture comprising an electrically-conductive material. For example, the batch mixture can comprise a metal and/or metal alloy. In particular embodiments, the batch mixture can contain at least one of iron (Fe), chromium (Cr), aluminum (Al), nickel (Ni), and the like.

[0059] In further embodiments, the intersecting cell walls 104, 104' can be formed from a composite that comprises a first phase of a porous material defining an internal, interconnected porosity, and a second phase of an electrically-conductive material that at least partially fills the internal, interconnected porosity of the first phase. In some embodiments, the material of the first phase is a porous ceramic, a porous glass-ceramic, and/or a porous glass material. In specific embodiments, the material of the first phase comprises cordierite, aluminum titanate, alumina, silicon carbide, silicon nitride, mullite, sappherine, spinel, calcium aluminate, zirconium phosphate, fl-spodumene, fl-eucryptite (LiAlSiO4), a cordierite-glass ceramic, fused silica, doped fused silica, and/or the like, including combinations thereof. In some embodiments, the electrically-conductive material of the second phase comprises metal and/or metal alloy particles, such as molybdenum, molybdenum-containing compounds, molybdenum disilicide (MoSi2), silicon carbide (SiC) doped with boron (B), aluminum (Al), or nitrogen (N), and the like.

[0060] Advantageously, the second phase can form a continuous, three-dimensional, interconnected, electrically conductive phase that provides a continuous, three-dimensional, electrically-conductive path laterally across the resistive heater body 100 (in a direction 108 perpendicular to the axial direction), such as between a first side 112 and an opposite second side 116 of the resistive heater body 100.

[0061] In embodiments, the resistive heater body 100 can have a defined channel density measured in terms of the average number of cells per square inch (cpsi). In some embodiments, the channel density can be from about 100 cpsi (31 cells/cm²) to about 600 cpsi (186 cells/cm²), including from about 100 cpsi to about 200 cpsi, from about 200 cpsi to about 300 cpsi, from about 300 cpsi to about 400 cpsi, from about 400 cpsi to about 500 cpsi, from about 500 cpsi to about 600 cpsi, and any combination of endpoints thereof.

[0062] In embodiments, the cell walls 104, 104' of the resistive heater body 100 can have a defined transverse wall thickness T_w of from about 2 mils to about 14 mils, including from about 2 mils to about 3 mils, from about 3 mils to about 4 mils, from about 4 mils to about 5 mils, from about 5 mils to about 6 mils, from about 6 mils to about 7 mils, from about 7 mils to about 8 mils, from about 8 mils to about 9 mils, from about 9 mils to about 10 mils, from about 10 mils to about 11 mils, from about 11 mils to about 12 mils, from about 12 mils to about 13 mils, from about 13 mils to about 14 mils, and any combination of endpoints thereof. [0063] In embodiments, the average size of a cell channel 102 of the resistive heater body 100 can be from about 1.0 mm to about 2.5 mm, including from about 1.0 mm to about 1.5 mm, from about 1.5 mm to about 2.0 mm, from about 2.0 mm to about 2.5 mm, and any combination of endpoints thereof.

[0064] Accordingly, the resistive heater body 100 can be formed from intersecting cell walls 104, 104' that enable electrical current to pass through such that the resistive heater body 100 is electrically-conductive between respective opposing sides 112, 116. In embodiments, one or more slots 106 can be formed within the resistive heater body 100 to increase the length of the electrically-conductive path between opposing sides 112, 116.

[0065] For example, as shown in FIG. 1, the resistive heater body 100 comprises a plurality of slots 106 extending transversely into the resistive heater body 100 from alternating directions along a direction 108 of the resistive heater body 100. That is, each slot 106 can extend from an outer periphery 118 of the resistive heater body 100 through the intersecting cell walls 104, 104' until reaching a terminal end 107 located within the interior of the resistive heater body 100. As such, the plurality of slots 106 can define a serpentine electrically-conductive path from a first side 112 of the resistive heater body 100 to a second side 116 of the resistive heater body 100.

[0066] In some embodiments, each of the slots 106 can extend axially from a first end face of the resistive heater body 100 to a second end face of the resistive heater body 100. In embodiments, each of the slots 106 can have a slot width of from about 1.0 mm to about 2.5 mm, including from about 1.0 mm to about 1.5 mm, from about 1.5 mm to about 2.0 mm, from about 2.0 mm to about 2.5 mm, and any combination of endpoints thereof, or of about the size of one cell channel 102. In particular embodiments, the terminal end 107 of one or more slots 106 can be spaced from an outer periphery 118 of the resistive heater body 100 by a predetermined distance (e.g., atleastfive cell channels, at most two cell channels, etc.). In some embodiments, as discussed in more detail below, the terminal end 107 of one or more slots 106 is spaced a predetermined distance from a covered portion of the resistive heater body 100. Further, although the slots 106 are shown as having a straight path from the outer periphery 118 of the resistive heater body 100 to a corresponding terminal end 107, it should be appreciated that the slots 106 can have other shapes or trajectories (as illustrated in FIGS. 16A and 16B).

[0067] In some embodiments, the plurality of slots 106 can be air gaps, or fully or partially filled with an electrically insulating material, such as aluminum oxide. In particular embodiments, the insulating material can have a coefficient of thermal expansion substantially equal to that of the composition of the intersecting cell walls 104, 104'.

[0068] In embodiments, the electrical conductivity along the conductive path of the resistive heater bodies 100 of the present disclosure can be at least about 300 S/cm, including at least about 500 S/cm, at least about 1,000 S/cm, and/or at least about 1,500 S/cm. In particular embodiments, the electrical conductivity along the conductive path of the resistive heater body 100 can be from about 300 S/cm to about 2,500 S/cm, including from about 500 S/cm to about 2,000 S/cm, from about 1,000 S/cm to about 1,500 S/cm, and/or any combination of endpoints thereof.

[0069] According to the present disclosure, the resistive heater bodies (e.g., resistive heater body 100) disclosed herein comprise one or more current directing features proximal to a terminal end of a corresponding slot (e.g., a terminal end 107 of a slot 106). In embodiments, one or more of the plurality of slots 106 of a resistive heater body 100 can have a corresponding current directing feature. In some embodiments, each of the plurality of slots 106 of the resistive heater body 100 can have a corresponding current directing feature. In embodiments, the current directing features described herein can extend the entire length of the resistive heater body (i.e., can extend axially from one end face of the resistive heater body 100 to a second end face of the resistive heater body 100).

[0070] In particular embodiments, each current directing feature of a resistive heater body (e.g., resistive heater body 100) can be configured to adjust the path of an electrical current flowing through the resistive heater body away from a shortest distance pathway through the resistive heater body. Put another way, each current directing feature can be configured to redirect the path of an electrical current flowing through the resistive heater body towards a region of the resistive heater body remote from a terminal end of a corresponding slot (e.g., terminal end 107 of a slot 106).

[0071] In embodiments, each current directing feature of the resistive heater body can comprise an arrangement of modified cell channels (e.g., cell channels 102). For example, with reference to FIGS. 2A and 2B, certain modified cell channels 102 are illustrated according to various embodiments of the present disclosure. As shown, an array of intersecting cell walls 104, 104' form a plurality of cell channels 102A, 102B, 102C, 102D. The cell channel 102A is illustrated as having a single filleted comer 202. The cell channel 102B is illustrated as having two filleted comers 204. The cell channel 102C is illustrated as having a single chamfered comer 206. The cell channel 102D is illustrated as having a single beveled edge 208. And the cell channel 102E is illustrated as having two chamfered comers 210. Although certain filleted, chamfered, beveled, and/or otherwise partially-filled cell channels are mentioned, these examples are illustrative only and it should be appreciated that other regular and/or irregular geometries are disclosed.

[0072] In particular embodiments, each current directing feature of the resistive heater body can comprise an arrangement of thickened cell walls (e.g., walls 104, 104') in combination with an arrangement of modified cell channels (e.g., cell channels 102). As described herein, the arrangements of thickened cell walls and/or the arrangements of modified cell channels can extend the entire length of the resistive heater body (i.e., can extend axially from one end face of the resistive heater body 100 to a second end face of the resistive heater body 100).

[0073] In embodiments, with reference to FIG. 3, a portion of a resistive heater body 100 having a first current directing feature 300 is illustrated according to aspects of the present disclosure. As shown, the current directing feature 300 is arranged proximal to a terminal end 107 of a corresponding slot 106 of the resistive heater body 100. The current directing feature 300 comprises a first linear portion 302 extending in in a first direction DI perpendicular to a major direction of the slot 106 (i.e., direction D3), a second linear portion 304 extending in a second direction D2 perpendicular to the major direction D3 of the slot 106, and a middle / connecting portion 306 having an arrangement of modified cell channels that connect the first and second linear portions 302, 304.

[0074] In embodiments, the first and/or second linear portions 302, 304 of the current directing feature 300 can comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the thickness T_w of the intersecting cell walls 104, 104' outside of the linear portions 302, 304. Put another way, the first and/or second linear portions 302, 304 of the current directing feature 300 can comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the average thickness of the intersecting cell walls 104, 104' of the resistive heater body 100.

[0075] In embodiments, the thickness TF of the thickened cell walls 104, 104' of the first and/or second linear portions 302, 304 can be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination of endpoints thereof. [0076] In embodiments, the first and/or second linear portions 302, 304 of the current directing feature 300 can coincide with the terminal end 107 of the corresponding slot 106. For example, as shown in FIG. 3, the first and second linear portions 302, 304 extend along a cell wall 104 that also partially forms the terminal end 107 of the slot 106.

[0077] In embodiments, the first and/or second linear portions 302, 304 of the current directing feature 300 can extend in the first and second directions DI, D2, respectively, across a plurality of cell channels 102. In some embodiments, the first and/or second linear portions 302, 304 of the current direction feature 300 extend in the first and second directions DI, D2, respectively until reaching an adjacent slot 106.

[0078] In embodiments, the current directing feature 300 further comprises a middle portion 306 having an arrangement of modified cell channels that connect the first and second linear portions 302, 304. More specifically, the middle portion 306 of the current directing feature 300 comprises an arrangement of six cell channels 102 in a two-by-three grid. In the example of FIG. 3, the middle portion 306 comprises a first modified cell channel 102 with an outer chamfered comer, a second modified cell channel 102 with an opposing outer chamfered comer, and a first unmodified cell channel 102 separating the first and second modified cell channels 102 in a first direction. The middle portion 306 further comprises a third modified cell channel 102 having two interior chamfered comers adjacent to the first unmodified cell channel 102 in a second direction, where the third modified cell channel 102 is surrounded on top and bottom by unmodified cell channels 102.

[0079] With reference to FIG. 4, a portion of another resistive heater body 100 having a second current directing feature 400 is illustrated according to aspects of the present disclosure. As shown, the current directing feature 400 is arranged proximal to a terminal end 107 of a corresponding slot 106 of the resistive heater body 100, and comprises an arrangement of thickened cell walls (e.g., walls 104, 104') in combination with an arrangement of modified cell channels (e.g., cell channels 102).

[0080] In particular, the second current directing feature 400 comprises a first linear portion 402 extending in in a first direction DI perpendicular to a major direction of the slot 106 (i.e., direction D3), a second linear portion 404 extending in a second direction D2 perpendicular to the major direction D3 of the slot 106, and a middle / connecting portion 406 having an arrangement of modified cell channels that connect the first and second linear portions 402, 404. [0081] In embodiments, the first and/or second linear portions 402, 404 of the current directing feature 400 comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the thickness T_w of the intersecting cell walls 104, 104' outside of the linear portions 402, 404. Put another way, the first and/or second linear portions 402, 404 of the current directing feature 400 can comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the average thickness of the intersecting cell walls 104, 104' of the resistive heater body 100.

[0082] In embodiments, the thickness TF of the thickened cell walls 104, 104' of the first and/or second linear portions 402, 404 can be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination of endpoints thereof. [0083] In embodiments, the first and/or second linear portions 402, 404 of the current directing feature 400 can be spaced one or more cell channels 102 away from with the terminal end 107 of the corresponding slot 106 (i.e., in a direction towards the outer periphery 118 of the resistive heater body 100). For example, as shown in FIG. 4, the first and second linear portions 402, 404 extend along a cell wall 104 that is separated from the terminal end 107 of the slot 106 by two cell channels in the direction D3.

[0084] In embodiments, the first and/or second linear portions 402, 404 of the current directing feature 400 can extend in the first and second directions DI, D2, respectively, across a plurality of cell channels 102.

[0085] In embodiments, the current directing feature 400 further comprises a middle portion 406 having an arrangement of modified cell channels that connect the first and second linear portions 402, 404. More specifically, the middle portion 406 of the current directing feature 400 comprises an arrangement of three cell channels 102 in a one-by-three grid. In the example of FIG. 4, the middle portion 406 comprises a first modified cell channel 102 with an outer chamfered comer, a second modified cell channel 102 with two chamfered comers, and a third modified cell channel 102 with an opposing outer chamfered comer. As shown, the linear portions 402, 404 connect with the middle portion 406 at unchamfered comers of the arrangement of cell channels 102.

[0086] With reference to FIG. 5, a portion of another resistive heater body 100 having a third current directing feature 500 is illustrated according to aspects of the present disclosure. As shown, the current directing feature 500 is arranged proximal to a terminal end 107 of a corresponding slot 106 of the resistive heater body 100, and comprises an arrangement of thickened cell walls (e.g., walls 104, 104') in combination with an arrangement of modified cell channels (e.g., cell channels 102).

[0087] In particular, the second current directing feature 500 comprises a first linear portion 502 extending in in a first direction DI perpendicular to a major direction of the slot 106 (i.e., direction D3), a second linear portion 504 extending in a second direction D2 perpendicular to the major direction D3 of the slot 106, and a middle / connecting portion 506 having an arrangement of modified cell channels that connect the first and second linear portions 502, 504.

[0088] In embodiments, the first and/or second linear portions 502, 504 of the current directing feature 500 comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the thickness T_w of the intersecting cell walls 104, 104' outside of the linear portions 502, 504. Put another way, the first and/or second linear portions 502, 504 of the current directing feature 500 can comprise thickened cell walls 104, 104' that have a thickness TF that is greater than the average thickness of the intersecting cell walls 104, 104' of the resistive heater body 100.

[0089] In embodiments, the thickness TF of the thickened cell walls 104, 104' of the first and/or second linear portions 502, 504 can be from about 5 mils to about 25 mils, including from about 5 mils to about 10 mils, from about 10 mils to about 15 mils, from about 15 mils to about 20 mils, from about 20 mils to about 25 mils, and any combination of endpoints thereof. [0090] In embodiments, the first and/or second linear portions 502, 504 of the current directing feature 500 can be spaced one or more cell channels 102 away from with the terminal end 107 ofthe corresponding slot 106 (e.g., in a direction away from an outer periphery 118 of the resistive heater body 100). For example, as shown in FIG. 5, the first and second linear portions 502, 504 extend along a cell wall 104 that is separated from the terminal end 107 of the slot 106 by one cell channel in a direction opposing direction D3.

[0091] In embodiments, the first and/or second linear portions 502, 504 of the current directing feature 500 can extend in the first and second directions DI, D2, respectively, across a plurality of cell channels 102. [0092] In embodiments, the current directing feature 500 further comprises a middle portion 506 having an arrangement of modified cell channels that connect the first and second linear portions 502, 504. More specifically, the middle portion 506 of the current directing feature 500 comprises an arrangement of eight cell channels 102 in a three-by-three grid. In the example of FIG. 5, the middle portion 506 comprises thickened cell walls 104' extending in direction D3 that at least partially border the terminal end 107 of the slot 106. These thickened cell walls 104' extend to two chamfered cell channels 102 that are separated by an unmodified cell channel 102. Centered on the terminal end 107 of the slot 106 and adjacent to the unmodified cell channel 102, the middle portion 506 comprises a modified cell channel 102 having two chamfered interior comers that is surrounded by two unmodified cell channels 102. [0093] As described herein, the one or more current directing features (e.g., current directing features 300, 400, 500) can be configured to adjust the path of an electrical current flowing through the resistive heater body 100 such that fewer cold regions are generated. In particular embodiments, for example, this means that more current is directed to outer regions of the resistive heater body 100 and away from the terminal ends of a plurality of slots (e.g., terminal ends 107 of slots 106).

[0094] With reference to FIG. 6, for example, the heating performance of a resistive heater body 100 having a comparative V-shaped current directing feature 600 centered at the terminal end 107 of a slot 106 is illustrated according to aspects of the present disclosure. As shown, the resistive heater body 100 experiences significant temperatures (i.e., at least about 500°C) around the slot 106 and the comparative current directing feature 600 produces region of moderate temperatures (i.e., between about 300°C and about 500°C), while regions further away from the slot 106 are significantly colder (i.e., between about 0°C and about 300°C). As a result, a fluid passing through the cell channels 102 in certain regions of the resistive heater body 100 will experience significantly different temperatures than a fluid passing through the cell channels 102 in other regions of the resistive heater body 100.

[0095] Turning to FIGS. 7, 8, and 9, the heating performance of the first, second, and third current directing features (shown in FIGS. 3, 4, and 5, respectively) are illustrated relative to the heating performance of the comparative current directing feature (shown in FIG. 6). As shown, the difference in temperature between the comparative example and the inventive examples is plotted, and therefore areas that experienced lower temperatures in the inventive example have a positive temperature change while areas that experienced higher temperatures in the inventive example have a negative temperature change. In particular, looking at the temperature differentials in non-fdleted portions of the resistive heater, it can be seen from FIGS. 7, 8, and 9 that the first, second, and third current directing features improve heating performance (i.e., higher temperatures) in areas further away from the slots 106.

[0096] With reference to FIGS. 10A-16B, also provided herein are the resistive heater bodies comprising a combination of one or more extended slots and one or more current directing features. In embodiments, the one or more current directing features can be one or more of the current directing features 300, 400, 500 described above, but can also comprise a continuous length of modified cell walls corresponding to a series of adjacent, partially-filled cell channels, as shown in FIGS. 10A-16B. In embodiments, the one or more extended slots can have a corresponding terminal end that is within a predefined distance from the outer periphery of the resistive heater body. In particular embodiments, a portion of the outer periphery of the resistive heater body can be covered (e.g., by a securing ring, etc.), and the one or more extended slots can have a corresponding terminal end that is within a predefined distance from the covered portion of the outer periphery.

[0097] For example, with reference to FIG. 10A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1002 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1002 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1004 of the resistive heater body 100.

[0098] In the example of FIG. 10A, the resistive heater body 100 comprises a current directing feature 1006 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1006 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. In embodiments, a portion of the current directing feature 1006 can be covered by the securing ring 140 and/or follow the contour of the securing ring 140. Further, as shown in FIG. 10A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1002 of the resistive heater body 100 that is covered by the securing ring 140 by at most one cell channel 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1002, including within less than two cell channels from the covered portion 1002, and/or within less than one cell channel from the covered portion 1002.

[0099] With reference to FIG. 10B, the heating performance of the resistive heater body 100 shown in FIG. 10A is illustrated. As shown, the current directing feature 1006 and the extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100. However, the current directing feature 1006 and the extended slot 106 also produce higher temperatures in a covered portion 1002 of the resistive heater body 100.

[0100] With reference to FIG. 11A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1102 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1102 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1104 of the resistive heater body 100.

[0101] In embodiments, the resistive heater body 100 comprises a current directing feature 1106 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1106 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. In the example of FIG. 11A, a portion of the current directing feature 1106 follows the contour of the securing ring 140 but is not covered by the securing ring 140.

[0102] Further, as shown in FIG. 11A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1102 of the resistive heater body 100 that is covered by the securing ring 140 by at most three cell channels 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1102, including within less than two cell channels from the covered portion 1102, and/or within less than one cell channel from the covered portion 1102.

[0103] With reference to FIG. 1 IB, the heating performance ofthe resistive heater body 100 shown in FIG. 11A is illustrated. As shown, the current directing feature 1106 and the extended slot 106 successfully reduce the temperatures in the covered portion 1002 ofthe resistive heater body 100 but leave a larger cold spot further away in an uncovered portion 1004 of the resistive heater body 100. Further, it can be seen that the current directing feature 1106 successfully keeps temperatures in the region of the heater body 100 adjacent to the securing ring 140 to a minimum. That is, in some embodiments, the current directing features 1106 can increase heating at some portions of the heater body 100 while not increasing temperatures in other portions (e.g., a portion covered by the securing ring 140).

[0104] With reference to FIG. 12A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1202 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1202 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1204 of the resistive heater body 100.

[0105] In the example of FIG. 12A, the resistive heater body 100 comprises a current directing feature 1206 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1206 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. The resistive heater body 100 further comprises a region 1208 of plugged cell channels, wherein the cell channels are filled to prevent any fluid flow. In embodiments, a portion of the current directing feature 1206 can be covered by the securing ring 140 and/or follow the contour of the securing ring 140.

[0106] Further, as shown in FIG. 12A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1002 of the resistive heater body 100 that is covered by the securing ring 140 by at most three cell channels 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1202, including within less than two cell channels from the covered portion 1202, and/or within less than one cell channel from the covered portion 1202.

[0107] With reference to FIG. 12B, the heating performance ofthe resistive heater body 100 shown in FIG. 12A is illustrated. As shown, the current directing feature 1206 and the extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118. While the plugged region 1208 of the resistive heater body 100 remains cold, there is no air flow through the plugged region 1208 and the current directing feature 1206 successfully increased temperatures near the plugged region 1208 where the cell channels 102 are notplugged (i.e., permit airflow). Additionally, it can be seen that the current directing feature 1206 successfully keeps temperatures in the region of the heater body 100 adjacent to the securing ring 140 to a minimum. That is, in some embodiments, the current directing features 1206 can increase heating at some portions of the heater body 100 while not increasing temperatures in other portions (e.g., a portion covered by the securing ring 140).

[0108] With reference to FIG. 13 A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1302 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1302 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1304 of the resistive heater body 100.

[0109] In the example of FIG. 13A, the resistive heater body 100 comprises a current directing feature 1306 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1306 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. In embodiments, a portion of the current directing feature 1306 can be covered by the securing ring 140 and/or follow the contour of the securing ring 140. In particular, unlike the current directing features 1006, 1106, 1206 where a portion of the current directing feature 1006, 1106, 1206 extends away from the contour of the securing ring 140, the entire length of the current directing feature 1306 follows the contour of the securing ring 140.

[0110] Further, as shown in FIG. 13A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1302 of the resistive heater body 100 that is covered by the securing ring 140 by at most two cell channels 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1302, including within less than two cell channels from the covered portion 1302, and/or within less than one cell channel from the covered portion 1302.

[0111] With reference to FIG. 13B, the heating performance of the resistive heater body 100 shown in FIG. 13A is illustrated. As shown, the current directing feature 1306 and the extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100. However, the current directing feature 1306 and the extended slot 106 also produce higher temperatures in a covered portion 1302 of the resistive heater body 100.

[0112] With reference to FIG. 14A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1402 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1402 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1404 of the resistive heater body 100.

[0113] In the example of FIG. 14A, the resistive heater body 100 comprises a current directing feature 1406 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1406 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. As shown, the current directing feature 1406 further comprises a series of adjacent cell channels 102 that are completely filled.

[0114] In embodiments, a portion of the current directing feature 1406 can be covered by the securing ring 140 and/or follow the contour of the securing ring 140. In particular, unlike the current directing features 1006, 1106, 1206 where a portion of the current directing feature 1006, 1106, 1206 extends away from the contour of the securing ring 140, the entire length of the current directing feature 1406 follows the contour of the securing ring 140.

[0115] Further, as shown in FIG. 14A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1402 of the resistive heater body 100 that is covered by the securing ring 140 by at most two cell channels 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1402, including within less than two cell channels from the covered portion 1402, and/or within less than one cell channel from the covered portion 1402.

[0116] With reference to FIG. 14B, the heating performance ofthe resistive heater body 100 shown in FIG. 14A is illustrated. As shown, the current directing feature 1406 and the extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0117] With reference to FIG. 15 A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1502 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1502 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1504 of the resistive heater body 100.

[0118] In the example of FIG. 15A, the resistive heater body 100 comprises a current directing feature 1506 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1506 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. In particular, the current directing feature 1506 comprises three adjacent cell channels 102 that each have one or more filleted cell walls 104, 104'.

[0119] Further, as shown in FIG. 15A, the slot 106 comprises a terminal end 107 that is spaced from the portion 1502 of the resistive heater body 100 that is covered by the securing ring 140 by at most three cell channels 102. Put another way, in embodiments, the resistive heater body 100 can comprise a slot 106 that extends into the resistive heater body 100 to within less than three cell channels from the covered portion 1502, including within less than two cell channels from the covered portion 1502, and/or within less than one cell channel from the covered portion 1502.

[0120] With reference to FIG. 15B, the heating performance of the resistive heater body 100 shown in FIG. 15A is illustrated. As shown, the current directing feature 1506 and the extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0121] With reference to FIG. 16A, a portion of a resistive heater body 100 and a securing ring 140 that covers a portion 1602 of the outer periphery 118 of the resistive heater body 100 are illustrated according to aspects of the present disclosure. In embodiments, the covered portion 1602 of the resistive heater body 100 does not receive or enable a fluid flow through the cell channels 102, which is instead directed through the uncovered portion 1604 of the resistive heater body 100. [0122] In the example of FIG. 16A, the resistive heater body 100 comprises a current directing feature 1606 proximal to a terminal end 107 of a slot 106, wherein the current directing feature 1606 comprises a continuous length of modified cell walls 104, 104' corresponding to a series of adjacent, partially-filled cell channels 102. In particular, the current directing feature 1606 comprises three adjacent cell channels 102 that each have one or more filleted cell walls 104, 104'.

[0123] Further, as shown in FIG. 16A, the slot 106 does not follow a straight-line path into the resistive heater body 100. In particular embodiments, each slot 106 extends into the resistive heater body 100 for at least a first length in at least a first direction, and at least a second length in at least a second direction. As shown, the slot 106 extends into the resistive heater body 100 for a first length in a first direction D3, a second length in a second direction D2, a third length in the first direction D3, and a fourth length in the second direction D2. Although one irregular slot 106 arrangement is shown, it should be appreciated that the slot 106 can extend into the resistive heater body 100 in a number of different directions (including diagonally) and for different lengths.

[0124] In embodiments, a slot 106 can extend into the resistive heater body 100 to within less than three cell channels from the covered portion 1602, including within less than two cell channels from the covered portion 1602, and/or within less than one cell channel from the covered portion 1602.

[0125] With reference to FIG. 16B, the heating performance of the resistive heater body 100 shown in FIG. 16A is illustrated. As shown, the current directing feature 1606 and the irregular extended slot 106 successfully produce increased temperatures in the resistive heater body 100 closer to the outer periphery 118 of the resistive heater body 100.

[0126] Also provided herein are fluid treatment systems comprising a resistive heater body 100 as described herein. In particular, the fluid treatment systems can be adapted to minimize light-off timing of an associated fluid treatment component (e.g., a catalyst-containing substrate) and thereby reduce undesirable emissions. For example, with reference to FIG. 17, a cross-sectional side view of a fluid treatment system 1700 comprising a catalyst-containing substrate 1725 and a resistive heater body 100 is illustrated according to aspects of the present disclosure. [0127] In embodiments, the catalyzed substrate 1725 can be a flow-through type of honeycomb substrate (e.g., having a plurality of channels formed by intersecting cell walls), which contains a catalyst material useful for capturing undesirable emissions from a fluid flow via a chemical reaction. In some embodiments, a catalyst material is also included in and/or on the walls of the cell channels, for example, by washcoating. The catalyst material can comprise one or more metal materials that operate to reduce a concentration of an exhaust pollutant in a flow of an exhaust gas, including but not limited to, nitrogen oxides (NO_X), carbon monoxide (CO), and unbumed hydrocarbons. The catalyst material can be a selective catalyst reduction (SCR) catalysts. In some embodiments, the catalyst material can be a metal component that is selected from the group consisting of platinum, palladium, rhodium, ruthenium, iridium, and combinations thereof, for example. In embodiments, the catalyst metal material can be gold, silver, copper, or iron. Other oxide catalyst materials such as oxides of aluminum, zeolite, ceria, lithium, magnesium, calcium, manganese, cobalt, nickel, copper, zinc, and silver can also be included as part of a catalyst washcoat. In some embodiments, the catalyst oxide material of the washcoat can be a SOx sorbent component such as Mg or Mn02, for example.

[0128] In embodiments, the resistive heater body 100 can be positioned adjacent to the catalyst substrate 1725 such that the resistive heater body 100 is upstream from the catalyst substrate 1725. As such, a fluid flow 1723 passing through the fluid treatment system 1700 can flow through the cell channels 102 of the resistive heater body 100 before reaching the cell channels of the catalyst substrate 1725. Put another way, the resistive heater body 100 can be positioned and configured to receive a fluid flow 1723 (e.g., into a plurality of cell channels 102) at a first end face and communicate the fluid flow 1623 out of a second end face to the catalyst substrate 1725.

[0129] In embodiments, an electrical potential can be applied to the resistive heater body 100 by a control system 1720 comprising a voltage driver 1722 that is connected to the resistive heater body 100 via electrodes. That is, the control system 1720 is operatively connected to the resistive heater body 100 and is configured to drive power to the heater body 100 at appropriate times (e.g., at various times during or before operation of an engine coupled to the fluid treatment system 1700). In embodiments, the control system 1720 is configured to control the timing, duration, and/or magnitude of the potential (e.g., voltage) applied to the resistive heater body 100. [0130] In particular embodiments, the control system 1720 further comprises an engine control unit (ECU) 1724. In embodiments, the voltage driver 1722 of the control system 1720 can control the potential applied to the resistive heater body 100 according to a desired thermal profde provided by the engine control unit 1724. The thermal profde can be adapted to reduce cold-start emissions by, for example, applying a potential to the resistive heater body 100 such that the fluid flow 1723 reaches a minimum temperature within a predetermined period of time. In embodiments, the minimum temperature achieved can be from about 250°C to about 650°C, and the predetermined period of time is between about 1.0 second and about 10 seconds. In further embodiments, the minimum temperature to be achieved via the resistive heater body 100 can be determined as a function of the flow rate of the exhaust gas 1723, temperature of the gas flow 1723 at the inlet of the body, heat transfer coefficient between the resistive heater body 100 and the gas flow 1723, and applied power based on a goal or desired outcome. For example, the control system 1720 can receive one or more inputs from temperature sensors 1626 and/or gas sensors 1728 distributed at various points within the treatment system 1700.

[0131] With reference to FIGS. 18A-18D, the effect of using a resistive heater body 100 having one or more current directing features as described herein are illustrated according to aspects of the present disclosure. More specifically, FIG. 18A illustrates the temperature profile of a substrate (e.g., substrate 1625) positioned downstream of a comparative resistive heater body, while FIGS. 18B-18D illustrate the temperature profiles of substrates (e.g., substrate 1725) positioned downstream of resistive heater bodies having current directing features 1306, 1406, 1506, respectively. As shown, a darker shading represents higher temperatures while the white areas represent regions of the substrate where the temperature is potentially not hot enough to convert all exhaust gas that passes through. As shown, the current directing features and slot arrangements described in the present disclosure diminish the size of cold regions and improve heating the catalyzed substrate downstream. Additionally, the current directing features and slot arrangements described herein eliminate the formation of hot spots on the heater body 100 that would reduce the overall heating uniformity.

[0132] It should be appreciated that all combinations of the foregoing concepts and any concepts discussed below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein. It should also be appreciated that terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0133] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0134] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” [0135] The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified.

[0136] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” [0137] As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified.

[0138] As used herein, although the terms first, second, third, etc. may be used herein to describe various elements or components, these elements or components should not be limited by these terms. These terms are only used to distinguish one element or component from another element or component. Thus, a first element or component discussed below could be termed a second element or component without departing from the teachings of the inventive concept.

[0139] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 grams to 10 grams” is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values). The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value; they are sufficiently imprecise to include values approximating these ranges and/or values.

[0140] As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise value specified, in some cases. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.” The term “about” may refer to plus or minus 10% of the indicated number. For example, “about 10%” may indicate a range of 9% to 11%, and “about 1” may mean from 0.9-1.1. Other meanings of “about” may be apparent from the context, such as rounding off, so, for example “about 1” may also mean from 0.5 to 1.4.

[0141] For the recitation of numeric ranges herein, each intervening number there between with the same degree of precision is explicitly contemplated. For example, for the range of 6- 9, the numbers 7 and 8 are contemplated in addition to 6 and 9, and for the range 6.0-7.0, the number 6.0, 6. 1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, and 7.0 are explicitly contemplated.

[0142] Unless otherwise noted, when an element or component is said to be “connected to,” “coupled to,” or “adjacent to” another element or component, it will be understood that the element or component can be directly connected or coupled to the other element or component, or intervening elements or components may be present. That is, these and similar terms encompass cases where one or more intermediate elements or components may be employed to connect two elements or components. However, when an element or component is said to be “directly connected” to another element or component, this encompasses only cases where the two elements or components are connected to each other without any intermediate or intervening elements or components.

[0143] In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively.

[0144] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0145] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

Claims

Claims What is claimed is:

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

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

3. The resistive heater body of claim 1, wherein the slots extend axially from a first end face of the resistive heater body to a second end face of the resistive heater body.

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

5. The resistive heater body of claim 1, wherein the middle portion of the one or more current directing features comprise one or more filleted and/or chamfered cell walls.

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

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

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

9. The resistive heater body of claim 8, wherein the middle portion of each of the one or more current directing features is centered one cell channel away from the terminal end of at least one of the plurality of slots.

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

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

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

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

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

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

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

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

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

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

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