Laminating process of three-way catalyst liner

Abstract

The invention discloses an automatic film covering process for a three-way catalyst liner. According to the technology, film coating equipment is adopted, and the core of the technology is that a plurality of heating plates in a heating box are divided into a plurality of temperature control areas including an upper heating area and a lower heating area. The temperature of the corresponding heating area is selectively set through the control unit according to a single-face or double-face film covering instruction. According to the method, the temperature zones are further set into an inlet zone, a middle zone and an outlet zone in the liner advancing direction, and the upper temperature and the lower temperature of each zone can be independently controlled. By means of fine zoning temperature control and automatic setting, different film covering requirements are self-adapted, uniform pasting of a film layer on the surface of a liner is achieved, and the product quality and the production efficiency are effectively improved.

Description

Technical Field

[0001] This invention relates to the field of automotive exhaust purification device manufacturing technology, and more specifically, to a coating process for a three-way catalytic converter gasket. Background Technology

[0002] The three-way catalytic converter is a key component in the exhaust purification system of an automotive engine. It typically houses a catalytic carrier, which is supported, sealed, and insulated from the metal housing by a gasket. To improve the mechanical strength of the gasket, especially its resistance to bending and surface cracking during use, a protective film is usually firmly adhered to one or both surfaces of the gasket.

[0003] Currently, the industry mostly uses heated roller pressing equipment for coating three-way catalytic converter liners. This type of process typically suffers from problems such as coarse division of the heating zone and insufficient temperature control precision. Specifically, the heating systems of existing equipment often control the temperature of the entire heating area as a whole, or only perform simple partitioning, making it difficult to accurately simulate and match the specific temperature profiles of the three stages required in the coating process: preheating, melting and bonding, and curing and shaping. This easily leads to uneven heating of the film layer, resulting in quality defects such as poor adhesion, blistering, or cracking.

[0004] Furthermore, existing technologies lack an intelligent and rapid temperature control mechanism to address the different process requirements of single-sided and double-sided lamination. In actual production, switching lamination types often requires operators to manually reset parameters for numerous temperature zones, a cumbersome and error-prone process. This reliance on manual experience not only results in low production efficiency but also makes it difficult to ensure consistent quality between different batches of products.

[0005] Therefore, there is an urgent need in this field for an automated coating method that can achieve precise zoned temperature control and automatically adapt to different coating process requirements, so as to fundamentally solve the technical problems of uneven coating and unstable quality. Summary of the Invention

[0006] In order to overcome the above-mentioned defects of the prior art, embodiments of the present invention provide a coating process for a three-way catalytic converter liner.

[0007] To achieve the above objectives, this invention provides a coating process for a three-way catalytic converter liner, using a coating device comprising a heating chamber and a control unit. The heating chamber contains a plurality of heating plates. The innovation lies in dividing the heating plates into multiple temperature control zones, including an upper heating zone configured to heat the upper surface of the liner and a lower heating zone configured to heat the lower surface of the liner. The control unit selectively sets the temperature of the upper heating zone and / or the lower heating zone, depending on whether the coating is single-sided or double-sided, to achieve uniform adhesion of the film to the liner surface.

[0008] Furthermore, the aforementioned temperature control zones include an inlet zone, a middle zone, and an outlet zone arranged along the direction of the liner's travel.

[0009] Furthermore, the aforementioned inlet zone includes an upper inlet temperature zone and a lower inlet temperature zone, the middle zone includes an upper middle temperature zone and a lower middle temperature zone, and the outlet zone includes an upper outlet temperature zone and a lower outlet temperature zone.

[0010] Furthermore, when performing single-sided lamination, only the temperatures of the upper inlet temperature zone, upper middle temperature zone, and upper outlet temperature zone are set. Furthermore, when performing double-sided lamination, the temperatures of the upper inlet temperature zone, lower inlet temperature zone, upper middle temperature zone, lower middle temperature zone, upper outlet temperature zone, and lower outlet temperature zone are set.

[0011] Furthermore, in the above-mentioned single-sided coating process, the temperature of the upper temperature zone is set to 135°C, the temperature of the upper middle temperature zone is set to 140°C, and the temperature of the upper temperature zone is set to 135°C.

[0012] Furthermore, during the double-sided lamination process, the temperatures of the upper inlet temperature zone, lower inlet temperature zone, upper middle temperature zone, lower middle temperature zone, upper outlet temperature zone, and lower outlet temperature zone are set independently.

[0013] Furthermore, the aforementioned entry zone, middle zone, and exit zone are each composed of several heating plates arranged in segments along the length of the heating box, and the number of heating plates contained in each zone is different.

[0014] Furthermore, the aforementioned control unit has multiple sets of temperature settings pre-stored for single-sided and double-sided lamination, and automatically recalls and sets the corresponding temperature settings according to the lamination type command input by the user.

[0015] Furthermore, the heating plate mentioned above is an infrared heating plate or a resistance heating plate.

[0016] The technical effects and advantages of this invention are as follows: This invention achieves precise temperature control during the lamination process, significantly improving product quality. By dividing the heating plate into inlet, middle, and outlet zones, and further subdividing them into upper and lower heating areas, a highly refined temperature field is constructed. This design can accurately simulate and match the ideal temperature curves of the three key stages in the lamination process: preheating, melting and bonding, and curing and shaping. This ensures that the film layer is heated evenly and adheres firmly to the gasket surface, effectively eliminating quality defects such as localized blistering and cracking, and fundamentally improving the gasket's flexural and crack resistance.

[0017] This invention achieves intelligent and flexible lamination processes, significantly improving production efficiency and product consistency. By controlling the pre-stored temperature parameters and linking them with lamination type commands, the invention enables a one-click automatic switching between single-sided and double-sided lamination modes. This completely changes the traditional operation mode that relies on manual parameter setting, not only avoiding human error and shortening production line changeover time, but also improving production efficiency. More importantly, it ensures absolute consistency of process parameters across different batches of products, guaranteeing product quality stability and reliability. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the internal structure of the heating chamber of the equipment used in the automatic coating process described in this invention.

[0019] Figure 2 Logic flowchart for temperature setting of the control unit described in this invention Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] The core of this invention lies in the partitioned design of the heating plate and its collaborative work with the control unit, which achieves high quality and automation of pad coating through precise temperature control.

[0022] First Implementation Example: System Structure and Basic Working Principle refer to Figure 1 The automatic lamination process of this invention employs a dedicated lamination device. The core of this device includes a heating chamber 1 and a control unit (not shown in the figure). Inside the heating chamber 1, several heating plates 21 are arranged in segments along its length. These heating plates 21 are divided into multiple temperature control zones in terms of physical structure and electrical control.

[0023] Specifically, these temperature control zones first include an upper heating zone 11 configured to heat the upper surface of the gasket and a lower heating zone 12 configured to heat the lower surface of the gasket. Further, as shown by the arrows in the diagram along the gasket's travel direction, the temperature control zones are divided into three main areas: an inlet zone 3, a middle zone 4, and an outlet zone 5. Each main area contains upper and lower parts; that is, inlet zone 3 includes an upper inlet temperature zone 3a and a lower inlet temperature zone 3b; middle zone 4 includes an upper middle temperature zone 4a and a lower middle temperature zone 4b; and outlet zone 5 includes an upper outlet temperature zone 5a and a lower outlet temperature zone 5b.

[0024] The control unit has multiple pre-stored temperature settings corresponding to single-sided and double-sided lamination, respectively. Operators only need to input the lamination type command through the human-machine interface, and the control unit will automatically call up and set the corresponding temperature parameters, achieving one-button operation. Working principle: During lamination, the pad is conveyed by a conveyor belt, passing sequentially through the inlet zone 3, middle zone 4, and outlet zone 5 of the heating chamber 1. Based on the preset lamination type (single-sided or double-sided), the control unit selectively activates the corresponding temperature zones of the upper heating zone 11 and / or the lower heating zone 12, allowing the film material to undergo preheating and softening, full melting and bonding, and stable curing processes, thereby achieving uniform and firm adhesion.

[0025] Second embodiment: Single-sided coating process When single-sided lamination is required, taking the lamination of the upper surface of the gasket as an example, the operator selects the "single-sided lamination" mode in the control unit. See also Figure 2 The control unit's workflow begins upon receiving the instruction "single-sided lamination." After judgment, it automatically retrieves pre-stored single-sided lamination temperature parameters. Specifically, as follows... Figure 1 As shown, the control unit only sets the temperature of the upper heating zone 11, that is, activates the upper inlet temperature zone 3a, the upper middle temperature zone 4a and the upper outlet temperature zone 5a, while all temperature zones 3b, 4b and 5b of the lower heating zone 12 remain closed or in a low-temperature standby state.

[0026] In a preferred temperature setting, the temperature of the upper inlet temperature zone 3a is set to 135°C, the temperature of the upper middle temperature zone 4a is set to 140°C, and the temperature of the upper outlet temperature zone 5a is set to 135°C. The gasket is initially heated and softened in inlet zone 3, then fully melts at a higher temperature in middle zone 4 and adheres to the gasket under the action of pressure rollers, finally solidifying in outlet zone 5. This process ensures uniformity of single-sided lamination and effectively improves the folding resistance of the gasket.

[0027] Third embodiment: Double-sided lamination process When double-sided lamination is required, the operator selects the "double-sided lamination" mode on the control unit. See also... Figure 2 After receiving the "double-sided lamination" command, the control unit determines and retrieves the pre-stored double-sided lamination temperature parameters. At this time, if... Figure 1As shown, the control unit will simultaneously set all temperature zones of the upper heating zone 11 and the lower heating zone 12, that is, the temperatures of the upper inlet temperature zone 3a, the lower inlet temperature zone 3b, the upper middle temperature zone 4a, the lower middle temperature zone 4b, the upper outlet temperature zone 5a, and the lower outlet temperature zone 5b are all activated and set independently.

[0028] The temperature of each zone can be finely adjusted according to the specific heat capacity and heat dissipation of the upper and lower surfaces of the gasket. For example, the upper inlet temperature zone 3a can be set to 135℃, the lower inlet temperature zone 3b to 130℃, the upper middle temperature zone 4a to 140℃, the lower middle temperature zone 4b to 138℃, the upper outlet temperature zone 5a to 135℃, and the lower outlet temperature zone 5b to 133℃. This independent and precise control ensures that both sides of the gasket achieve the best coating effect, thus improving the overall consistency of product quality.

[0029] It is understood that the above temperature values ​​are only a preferred embodiment. Depending on the specific material and thickness of the pad and the characteristics of the film material, the temperature setting value of each temperature zone can be independently adjusted within the parameter range stored in the control unit to ensure the best coating effect.

[0030] Fourth embodiment: Optimized configuration of heating plate To further optimize the heat field distribution and energy efficiency, the configuration of the heating plate 21 can be adjusted. For example... Figure 1 As shown, the inlet zone 3, middle zone 4, and outlet zone 5 are each composed of several heating plates 21 arranged in segments, and the number of heating plates 21 in each zone is different. For example, in a specific design, the middle zone 4, which requires higher heat to achieve full melting, is equipped with 6 heating plates 21, while the inlet zone 3 and outlet zone 5 are each equipped with 4 heating plates 21. This differentiated configuration based on power requirements makes temperature control more precise and efficient. The heating plates 21 can be infrared heating plates or resistance heating plates, selected according to different process requirements.

[0031] In summary, this invention, through the innovative combination of zoned heating and intelligent control, perfectly adapts to the different process requirements of single and double-sided coating, achieving high-quality and automated coating of three-way catalytic converter gaskets.

[0032] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection" and "linkage" should be interpreted broadly, and can be mechanical or electrical connection, or internal connection between two components, or direct connection. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationship. When the absolute position of the described object changes, the relative positional relationship may change. Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other. Finally: The above description is only a preferred embodiment of this invention and is not intended to limit this invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of this invention should be included within the protection scope of this invention.

Claims

1. A coating process for a three-way catalytic converter liner, using a coating equipment, the coating equipment comprising a heating chamber (1) and a control unit, wherein a plurality of heating plates (21) are arranged inside the heating chamber (1), characterized in that: The plurality of heating plates (21) are divided into multiple temperature control zones, the temperature control zones including an upper heating zone (11) configured to heat the upper surface of the pad and a lower heating zone (12) configured to heat the lower surface of the pad; the temperature of the upper heating zone (11) and / or the lower heating zone (12) is selectively set by the control unit according to whether the film covering type is single-sided or double-sided, so as to achieve uniform adhesion of the film on the pad surface.

2. The automatic coating process for a three-way catalytic converter gasket according to claim 1, characterized in that: The temperature control zone includes an inlet zone (3), a middle zone (4), and an outlet zone (5) arranged along the direction of the liner's travel.

3. The automatic coating process for a three-way catalytic converter liner according to claim 2, characterized in that: The inlet zone (3) includes an upper inlet temperature zone (3a) and a lower inlet temperature zone (3b), the middle zone (4) includes an upper middle temperature zone (4a) and a lower middle temperature zone (4b), and the outlet zone (5) includes an upper outlet temperature zone (5a) and a lower outlet temperature zone (5b).

4. The automatic coating process for a three-way catalytic converter gasket according to claim 3, characterized in that: When performing single-sided coating, only the temperatures of the upper inlet temperature zone (3a), upper middle temperature zone (4a), and upper outlet temperature zone (5a) are set.

5. The automatic coating process for a three-way catalytic converter gasket according to claim 3, characterized in that: When performing double-sided lamination, the temperatures of the upper inlet temperature zone (3a), lower inlet temperature zone (3b), upper middle temperature zone (4a), lower middle temperature zone (4b), upper outlet temperature zone (5a), and lower outlet temperature zone (5b) are set.

6. The automatic coating process for a three-way catalytic converter gasket according to claim 4, characterized in that: When applying the film to one side, the temperature of the upper temperature zone (3a) is set to 135°C, the temperature of the upper middle temperature zone (4a) is set to 140°C, and the temperature of the upper temperature zone (5a) is set to 135°C.

7. The automatic coating process for a three-way catalytic converter gasket according to claim 5, characterized in that: During the double-sided coating process, the temperatures of the upper temperature zone (3a), lower temperature zone (3b), upper middle temperature zone (4a), lower middle temperature zone (4b), upper temperature zone (5a), and lower temperature zone (5b) are set independently.

8. The automatic coating process for a three-way catalytic converter gasket according to claim 2, characterized in that: The inlet (3), middle (4) and outlet (5) are each composed of several heating plates (21) arranged in segments along the length of the heating box (1), and the number of heating plates (21) contained in each area is different.

9. The automatic coating process for a three-way catalytic converter gasket according to claim 1, characterized in that: The control unit has multiple sets of temperature settings pre-stored for single-sided and double-sided lamination, and automatically calls and sets the corresponding temperature settings according to the lamination type command input by the user.

10. The automated coating process for a three-way catalytic converter liner according to claim 1, characterized in that: The heating plate (21) is an infrared heating plate or a resistance heating plate.

Images