Systems and methods for electrically heating a catalyst with a honeycomb body having radial walls

An electrical heater, for heating an exhaust flow comprising:

• a honeycomb body comprising:
• a honeycomb structure comprising a central axis extending longitudinally therethrough and a plurality of interconnected walls, the interconnected walls comprising:
• a plurality of radial walls, each radial wall extending at least partially along a radius of the honeycomb body between the central axis and an outermost periphery of the honeycomb body;
• and
• a plurality of angular walls arranged concentrically with respect to the central axis and spanning between the radial walls;
• and
• a plurality of cells defined by the interconnected walls;
• a first electrode disposed at the central axis;
• and
• a second electrode disposed radially outwardly of the central axis and in electrical communication with the first electrode via one or more of the interconnected walls that are located between the first electrode and second electrode,
• wherein the radial walls are thicker than the angular walls.

A method for heating a catalytic material, comprising the steps of:

• applying an electric potential difference across a first electrode located at a central axis of a first honeycomb body and a second electrode located on the honeycomb body radially outwardly from the first electrode to heat an exhaust stream flowing through the first honeycomb body, wherein the honeycomb body comprises a plurality of intersecting walls comprising a plurality of radial walls, each radial wall extending at least partially along a radius of the honeycomb body between the central axis and an outermost periphery of the honeycomb body, at least some of the plurality of radial walls angularly spaced from each other about the central axis and a plurality of angular walls arranged concentrically with respect to the central axis and spanning between the radial walls, wherein the electric potential difference creates a flow of current through the intersecting walls located between the first electrode and the second electrode that generates resistive heating in the intersecting walls;
• and
• directing the exhaust stream to a second honeycomb body downstream of the first honeycomb body, wherein the second honeycomb body comprises the catalytic material,
• wherein the honeycomb body comprises a first resistive region separated from a second resistive region by a transitional angular wall, wherein the first resistive region comprises fewer radial walls than the second resistive region, the first resistive region being located nearer to the central axis than the second resistive region and both the first resistive region and the second resistive region being located between the first and second electrodes.