Abstract: A method of manufacturing a pedestal includes having a support plate including a substrate, an electric element embedded in the substrate, and a conductive member connected to the electric element, preparing a tubular shaft that defines a chamber, securing the tubular shaft to the support plate, the conductive member being exposed in the chamber of the tubular shaft, and applying a protective layer on the conductive member by an atomic layer deposition (ALD) process. A system for manufacturing the pedestal and a pedestal are also provided in the present disclosure.

Abstract: A control system includes an electric heater disposed within an exhaust fluid flow pathway, and a control device for receiving at least one input selected from the group consisting of temperature readings along the exhaust fluid flow pathway, alternator power/current/voltage, battery power/current/voltage/state of charge, IAT and EAT profiles, mass flow rate of an exhaust fluid flow, NH3 slip, TCR characteristics of the heater, alternator speed, engine speed, state of aging of an aftertreatment component, state of aging of engine, aging degradation characteristics, a dosing rate and a temperature of DEF, NH3 storage condition of aftertreatment system, an ambient temperature, and combinations thereof. The control device modulates power to the heater based on the at least one input such that the heater provides different power output as a function of the at least one input and a continuously variable power output during operation of the exhaust system.

Abstract: A method of constructing a heater includes the steps of forming a sintered assembly including a ceramic substrate and a plurality of first slugs embedded therein, forming a functional element on one of opposing surfaces of the sintered assembly such that the functional element is connected to the plurality of first slugs, and forming a monolithic substrate in which the functional element and the plurality of first slugs are embedded.

Abstract: A ceramic pedestal assembly and a method of forming a ceramic pedestal assembly is provided. The ceramic pedestal assembly includes a ceramic substrate defining an upper surface and a lower surface, at least one via extending through the ceramic substrate, an upper conductive foil layer extending across the upper surface of the ceramic substrate and a lower conductive foil layer extending across the lower surface of the ceramic substrate. Each via includes an upper via defining a cavity and a lower via defining a corresponding tapered insert. In one form, the upper via, the lower via, and the conductive foil layers define a material having a melting temperature greater than 2,000° C. and a CTE less than or equal to the ceramic substrate.

Abstract: A support pedestal is provided that includes a substrate having a top resistive layer defining a first set of zones and a bottom resistive layer defining a second set of zones. Each zone of the first and second set of zones is coupled to at least two electric terminals from among a plurality of electric terminals, and a total number of electric terminals is less than or equal to a total of the first and second set of zones.

Abstract: The present disclosure relates to a sensing system and method that includes a plurality of resistive elements coupled to a plurality of nodes and a control system configured to index through a plurality of modes to measure an electrical characteristic for each resistive element. Each mode of the plurality of modes represents a different combination of power, return, or open circuit condition applied to each of the plurality of nodes, and the control system is configured to calculate, for each of the modes, a total power consumed by the system and a power consumed by each of the resistive elements based on the measured electrical characteristics, to determine a physical parameter.

Abstract: The present disclosure is directed toward a method that includes acquiring, by an imaging device, a thermal image of a heating surface of a heater assembly. The heater assembly includes a heating surface for heating a heating target, and the heating surface defines a plurality of heating zones. The further includes determining variations in the plurality of heating zones based on the thermal image of the heating surface. The the thermal image includes a plurality of pixels corresponding to the plurality of heating zones in the heater assembly.

Abstract: A method of constructing a heater includes providing a substrate, forming at least one trench into the substrate, depositing a functional material onto the substrate and into the at least one trench to form a functional element, and providing an electrical termination in contact with the functional element.

Abstract: A method of controlling a heating system includes: providing a heater bundle comprising a plurality of heater assemblies, each heater assembly comprising a plurality of heater units, each heater unit defining at least one independently controlled heating zone; supplying power to each of the heater units through power conductors electrically connected to each of the independently controlled heating zones in each of the heater units; and modulating power supplied to each of the heater units.

Abstract: A heater system includes a heater bundle and a power supply device. The heater bundle includes a plurality of heater assemblies and a plurality of power conductors. The heater assembly includes a plurality of heater units, each heater unit defining at least one independently controlled heating zone. The power conductors are electrically connected to each of the independently controlled heating zones in each of the heater units. The power supply device is configured to modulate power to each of the independently controlled heater zones of the heater units through the power conductors.

Abstract: An active temperature measurement system includes at least one grounded thermocouple and a processor in communication with the at least one grounded thermocouple. The processor is configured to receive measurements from the at least one grounded thermocouple. The at least one grounded thermocouple is biased by an isolated voltage when the processor is receiving a measurement from the at least one grounded thermocouple.

Abstract: A heater assembly is provided that includes a substrate having opposed end portions defining raised flanges, a slot extending between the opposed end portions, and opposed chamfered surfaces extending along the slot and across the raised flanges. A plurality of layers are disposed onto the substrate, along with a pair of terminal pads. A protective cover defining at least one aperture is disposed over the layers and is secured to the raised flanges and the opposed chamfered surfaces of the substrate, and the aperture is disposed proximate the terminal pads. A pair of lead wires is secured to the pair of terminal pads, and a lead cap assembly is disposed around the pair of lead wires and is secured to the protective cover.

Abstract: A heater assembly includes a continuous series of perforated helical members and a plurality of heating elements. The perforated helical members cooperate to define a geometric helicoid disposed about a longitudinal axis of the heater assembly. Each perforated helical member defines opposed edges and a predetermined pattern of perforations. The perforations extend through each perforated helical member parallel to the longitudinal axis. The heating elements extend through the perforations.

Abstract: A layered heater system is provided, which includes an engineered substrate, a heater substrate disposed on the engineered substrate, a resistive element layer formed proximate the heater plate, and a protective layer formed on the resistive element layer. Terminal pads are formed over at least a portion of the resistive element layer and are exposed through the protective layer. The engineered substrate includes a plurality of walls which extend in a thickness direction of the engineered substrate and which have a thickness engineered for specific heat transfer requirement.

Abstract: An exhaust system is provided that includes an exhaust aftertreatment unit, first and second exhaust pathway in communication with and upstream of the exhaust aftertreatment unit, a thermally activated flow control device operable in a first and second mode, and a thermal storage device. In the first mode, the flow control device permits exhaust to flow to the aftertreatment unit through the first pathway and inhibits flow through the second pathway. In the second mode, the flow control device permits exhaust flow to the aftertreatment unit through the second pathway and inhibits flow through the first pathway. The flow control device may switch between the first and second modes based on a change of temperature. The thermal storage device is within the second pathway, stores thermal mass, and provides thermal insulation to enable a catalyst of the aftertreatment unit to maintain a predetermined temperature for a predetermined time.

Abstract: A method of manufacturing a layered heater includes: applying a dielectric material on a substrate to form a dielectric layer; thermal-spraying a resistive material on the dielectric layer to form a resistive layer on the dielectric layer; forming a plurality of conductive overlays at predetermined locations on the substrate; and forming a plurality of cuts into the resistive layer by laser cutting to form a resistive circuit pattern that overlaps the conductive overlays.

Abstract: A fluid sensor system detects one or more performance characteristics of a heating system that heats a fluid. The sensor system includes a probe having a finite length a portion of which is to be immersed in the fluid. The probe includes a resistive heating element and a fluid temperature sensor for measuring one or more performance characteristics, wherein the fluid temperature sensor is configured to measure a fluid temperature, and the resistive heating element is operable as a heater to create a temperature differential between the fluid and air to detect the fluid, and as a sensor to measure a fluid level.

Abstract: A layered heater is provided that includes a sensor layer formed by a layered process having a plurality of independently controllable zones, and a resistive heating layer disposed adjacent the sensor layer. In one form, the sensor layer is formed of a material having a relatively high temperature coefficient of resistance (TCR) and the resistive heating layer is formed of a material having a relatively low TCR.

Abstract: A wireless sensor assembly includes a housing defining a first aperture for receiving an external sensor, and a second aperture defining a communication port, a wireless power source mounted within the housing, and electronics mounted to the housing and configured to receive power from the wireless power source and to be in electrical communication with the external sensor. The electronics include a wireless communications component, and firmware configured to manage a rate of data transmittal from the wireless communications component to an external device. The communication port is configured to receive a wire harness connected to the external sensor.

Abstract: An assembly, which in one form is a pedestal, includes an upper member, a lower member bonded to the upper member, and a thermal phase diffuser disposed between the upper member and the lower member within a hermetically sealed volume. The thermal phase diffuser diffuses heat by way of a phase change of a working fluid within the hermetically sealed volume. The assembly/pedestal is capable of operating at high temperatures, in excess of 1000° C., with a high degree of temperature uniformity, and in one form is an aluminum nitride (AlN) material.