US 12,286,917 B2
High power density insulated exhaust heating system
Mark D. Everly, St. Charles, MO (US); Jeremy Ohse, St. Louis, MO (US); David P. Culbertson, Bristol, WI (US); Richard T. Williams, Genoa City, WI (US); George Jambor, Burlington, WI (US); and Jacob Wilson, St. Charles, MO (US)
Assigned to WATLOW ELECTRIC MANUFACTURING COMPANY, St. Louis, MO (US)
Filed by WATLOW ELECTRIC MANUFACTURING COMPANY, St. Louis, MO (US)
Filed on Jan. 19, 2024, as Appl. No. 18/417,448.
Application 18/417,448 is a continuation of application No. 17/873,227, filed on Jul. 26, 2022, granted, now 11,913,365.
Application 17/873,227 is a continuation of application No. 17/535,096, filed on Nov. 24, 2021, granted, now 11,585,252, issued on Feb. 21, 2023.
Application 17/535,096 is a continuation of application No. 17/411,352, filed on Aug. 25, 2021, granted, now 11,408,314, issued on Aug. 9, 2022.
Application 17/411,352 is a continuation of application No. 16/806,175, filed on Mar. 2, 2020, granted, now 11,131,227, issued on Sep. 28, 2021.
Application 16/806,175 is a continuation of application No. 15/448,200, filed on Mar. 2, 2017, granted, now 10,598,064, issued on Mar. 24, 2020.
Claims priority of provisional application 62/415,042, filed on Oct. 31, 2016.
Prior Publication US 2024/0151173 A1, May 9, 2024
Int. Cl. F01N 3/20 (2006.01); F01N 3/027 (2006.01); F23G 7/00 (2006.01); H05B 3/48 (2006.01)
CPC F01N 3/2013 (2013.01) [F01N 3/027 (2013.01); F23G 7/00 (2013.01); H05B 3/48 (2013.01); F01N 2240/16 (2013.01); F01N 2450/22 (2013.01); H05B 2203/014 (2013.01); H05B 2203/022 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An exhaust gas heater system for an exhaust system of an internal combustion engine, the exhaust gas heater system comprising:
a tubular housing comprising an outer peripheral wall defining a tubular shape disposed about a central axis and defining an interior hollow space configured to receive exhaust gas from an exhaust pipe of the exhaust system such that the exhaust gas flows through the interior hollow space; and
a heating element including a first end and a second end, the heating element including an electrically conductive resistance element between the first and second ends and within the interior hollow space, the electrically conductive resistance element forming a first section and a second section, wherein the first section follows a first tortuous path that proceeds away from the first end until reaching a start of the second section, wherein the second section starts at an end of the first section and follows a second tortuous path that proceeds away from the start of the second section until reaching the second end, wherein the first and second ends extend radially outward of the outer peripheral wall on a same side, relative to the central axis, of the outer peripheral wall to receive power from outside the hollow space; and
a support structure including a plurality of alternate ridges and grooves and supporting the electrically conductive resistance element at a plurality of discrete locations along the first and second tortuous paths, wherein support structure extends axially upstream and/or downstream of the electrically conductive resistance element at the discrete locations.