US 12,102,962 B2
Composite structures, heater apparatus, fast light-off exhaust aftertreatment systems, and methods of manufacturing and using same
Douglas Munroe Beall, Painted Post, NY (US); and Vishwanath Ganpat Deshmane, Chesterbrook, PA (US)
Assigned to Corning Incorporated, Corning, NY (US)
Filed by CORNING INCORPORATED, Corning, NY (US)
Filed on Mar. 3, 2023, as Appl. No. 18/117,112.
Application 18/117,112 is a division of application No. 17/387,275, filed on Jul. 28, 2021, granted, now 11,628,401.
Prior Publication US 2023/0201771 A1, Jun. 29, 2023
Int. Cl. B01D 53/24 (2006.01); B01D 53/94 (2006.01); F01N 3/035 (2006.01); H05B 3/00 (2006.01); H05B 3/12 (2006.01)
CPC B01D 53/9454 (2013.01) [F01N 3/035 (2013.01); H05B 3/00 (2013.01); H05B 3/12 (2013.01); F01N 2250/02 (2013.01); F01N 2330/04 (2013.01); F01N 2330/06 (2013.01); F01N 2330/14 (2013.01); F01N 2330/34 (2013.01); F01N 2370/02 (2013.01); H05B 2203/006 (2013.01); H05B 2203/017 (2013.01); H05B 2203/024 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A method of manufacturing a composite structure, comprising:
subjecting a base structure comprising a porous material to an electrically conductive particle-containing slurry to form a particle-loaded body by depositing the electrically conductive particles at least within the interconnected porosity; and
firing the particle-loaded body to sinter the electrically conductive particles together into a continuous, three-dimensional, interconnected, electrically conductive phase located within the interconnected porosity of the base structure,
wherein the base structure comprises a monolithic honeycomb body of the porous material and the monolithic honeycomb body comprises an array of intersecting walls that form a plurality of channels extending in an axial direction through the body such that adjacent channels are located on opposite sides of each wall, and each wall has a wall thickness that is defined between the opposite sides of that wall, and the wall thicknesses of a plurality of the walls extend in a lateral direction that is perpendicular with respect to the axial direction, and
wherein the electrically conductive particles, from which the electrically conductive phase is formed, are deposited sufficiently within the interconnected porosity such that the electrically conductive phase creates a continuous electrical path that extends in the lateral direction across the body by extending in the lateral direction through the wall thicknesses of the walls in the plurality of walls in the lateral direction perpendicular to the axial direction.