Diesel particulate filter with zoned resistive heater
View Patent ↗A diesel particulate filter assembly comprises a diesel particulate filter (DPF) and a heater assembly. The DPF filters a particulate from exhaust produced by an engine. The heater assembly has a first metallic layer that is applied to the DPF, a resistive layer that is applied to the first metallic layer, and a second metallic layer that is applied to the resistive layer. The second metallic layer is etched to form a plurality of zones.
1. A diesel particulate filter assembly comprising:
a diesel particulate filter (DPF) that filters a particulate from exhaust produced by an engine; and
a heater assembly having a first metallic layer that is applied to said DPF, a resistive layer that is applied to said first metallic layer, and a second metallic layer that is applied to said resistive layer, wherein said second metallic layer is etched to form a plurality of zones.
2. The diesel particulate filter assembly of claim 1 further comprising an end plug that is inserted into said second metallic layer to close a channel of said DPF,
wherein said resistive layer is disposed downstream of said end plug.
3. The diesel particulate filter assembly of claim 1 wherein said first metallic layer is applied to said DPF by dip-coating.
4. The diesel particulate filter assembly of claim 3 wherein said first metallic layer is embedded into a wall of said DPF.
5. The diesel particulate filter assembly of claim 3 wherein said resistive layer is applied to said first metallic layer by dip-coating.
6. The diesel particulate filter assembly of claim 5 wherein said second metallic layer is applied to said resistive layer by dip-coating.
7. A system comprising:
the diesel particulate filter assembly of claim 1 ; and
a heater power module that is in electrical communication with each of said zones, and that selectively applies at least one of a voltage and a current to selected ones of said zones.
8. A method comprising:
applying a first metallic layer to a diesel particulate filter (DPF);
applying a resistive layer to said first metallic layer;
applying a second metallic layer to said resistive layer; and
etching said second metallic layer into a plurality of zones.
9. The method of claim 8 further comprising inserting an end plug into said second metallic layer to close a channel of said DPF,
wherein said resistive layer is disposed downstream of said end plug.
10. The method of claim 8 wherein said first metallic layer is applied to said DPF by dip-coating.
11. The method of claim 10 wherein said applying said first metallic layer to said DPF embeds said first metallic layer into a wall of said DPF.
12. The method of claim 10 wherein said resistive layer is applied to said first metallic layer by dip-coating.
13. The method of claim 12 wherein said second metallic layer is applied to said resistive layer by dip-coating.
14. The method of claim 8 further comprising:
selecting ones of said zones; and
selectively applying at least one of a voltage and a current to said selected ones of said zones.