Resistive heater substrates and methods of manufacturing resistive heater substrates

A method of selectively coating an outer periphery of a resistive heater body, the method comprising:

• masking a first end face of the resistive heater body, the resistive heater body comprising a plurality of channels formed by interconnected walls, wherein the interconnected walls comprise a ceramic-containing material;
• mounting the resistive heater body into a vacuum fixture at the second end face of the resistive heater body;
• while mounted to the vacuum fixture, submerging at least a portion of the resistive heater body into a slurry such that the slurry contacts at least an outer periphery of the resistive heater body, wherein the slurry comprises metal and/or metal alloy particles;
• applying a vacuum pressure to the resistive heater body via the vacuum fixture at least while the portion of the resistive heater body is submerged in the slurry;
• removing the resistive heater body from the slurry;
• and
• drying the resistive heater body at a first temperature for a first period of time.

A method of manufacturing a resistive heater body having one or more conductive bases formed at one or more outer surfaces of the resistive heater body, the method comprising:

• providing a resistive heater body, wherein the resistive heater body comprises:
• (i) a plurality of channels formed by interconnected walls, wherein the interconnected walls comprise a ceramic-containing material;
• and (ii) a conductive material infiltrating at least a first porous peripheral region of the resistive heater body;
• applying an organometallic mixture to at least a first surface of the resistive heater body adjacent to at least the first porous peripheral region of the resistive heater body;
• drying the resistive heater body and the applied organometallic mixture at a first temperature for a first period of time;
• and
• heating the ceramic honeycomb body and the applied organometallic mixture at a second temperature for a second period of time to sinter the conductive material infiltrating at least the first porous peripheral region of the resistive heater body to the organometallic mixture and thereby form at least a first conductive base.