Method of manufacture of a plasma reactor with curved shape for treating auto emissions

Abstract

A method for preparing a non-thermal plasma reactor reactor characterized by multiple concentric exhaust channels and multiple concentric conductor channels having alternating polarity, each connected to its respective polarity via bus paths is provided. The method comprises forming a substrate having a curved, swept shape comprising a thick outer wall surrounding a plurality of channels separated by dielectric barriers, coating selected channels with a conductive material to form conductor channels capable of forming an electric field around uncoated exhaust channels. Masking is employed to effect selective coating of conductive material while preventing the conductive material from being applied to non-value added areas. A first mask is employed to apply conductive material forming conductor channels and bus paths. An additional mask may be employed to cover the conductor channels and bus paths with a sealant. The method minimizes manufacturing steps as compared to prior methods. For example, all of the substrate channels are coated at the same time. Further, firing cycles occur with the entire substrate rather than as multiple pieces coated and fired separately.

Dependencies are inferred from the claim text.