Three-way catalyst cone and processing technology thereof
By using a method of integral molding and single outer wall welding, the problems of complicated processing procedures and unstable quality of three-way catalytic cones have been solved, achieving efficient and low-cost production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Filing Date
- 2026-05-22
- Publication Date
- 2026-07-14
AI Technical Summary
The existing three-way catalytic converter cone processing procedures are cumbersome, inefficient, have unstable product quality, and are costly.
The method of integral molding is adopted to reduce the molding and welding processes. The conical ring-shaped structure is formed by molding the plate and then welded together on the outer wall in one step.
It simplifies the processing flow, improves production efficiency and product precision, reduces production costs, minimizes the impact of thermal deformation, and ensures product quality.
Smart Images
Figure CN122383458A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of automotive three-way catalytic converter cone processing technology, specifically, it relates to a three-way catalytic converter cone and its processing technology. Background Technology
[0002] In the production of three-way catalytic converters, the quality of the processing technology directly affects production efficiency, product quality, and cost. The three-way catalytic converter cone has an irregular conical annular structure. In the current production technology, the whole is usually processed into two half-shells. The two half-shells are each molded from two plates, and then the two molded half-shells are welded together in two stages to form a conical annular shape.
[0003] Chinese invention patent application CN 110552762 A discloses an automotive air intake cone and its processing technology, which is formed by welding the two sides of a symmetrical first half-shell and a second half-shell together; as shown... Figure 1 The three-way catalytic cone shown is formed by overlapping and welding the two sides of the first half shell (1) and the second half shell (2) which have significantly different sizes. Both the inner and outer walls are welded, requiring a total of four welds to form four weld passes (3).
[0004] Both of the above methods involve welding two halves of the shell, resulting in a cumbersome process. Each molding process requires a mold, and the double molding increases the possibility of cumulative errors, affecting product precision. The welding process also requires multiple positioning and clamping operations, which is not only inefficient but can also lead to inconsistent product quality due to welding heat deformation. Furthermore, multiple processes mean greater investment of manpower and resources, increasing production costs. Therefore, it is essential to improve the processing technology of the three-way catalytic converter cone, reducing the number of processes and improving the processing efficiency and quality. Summary of the Invention
[0005] The purpose of this invention is to provide a three-way catalytic converter cone and its processing technology, which solves the technical problems in related technologies such as the large number of processing steps and the need to improve processing efficiency and quality of automotive three-way catalytic converter cones.
[0006] At least one embodiment of the present invention provides a three-way catalytic cone, including a main body, the main body being a conical annular shape, having a first interface at one end and a second interface at the other end, the first interface being larger than the second interface, the main body being molded from a plate, the plate having a first edge on one side and a second edge on the other side, the first edge being welded to the second edge, the first edge extending from the first interface to the second interface.
[0007] For example, at least one embodiment of this disclosure provides a three-way catalytic cone, wherein the first joint is the shortest distance along the main body cylinder wall from the first interface to the second interface.
[0008] At least one embodiment of the present invention also provides a three-way catalytic cone and a processing method thereof, for processing the three-way catalytic cone, including the following steps: S1. The sheet metal is processed to obtain a molding blank, and the molding blank has a first joint edge and a second joint edge on both sides; S2. The molding blank is cone-shaped and molded so that the first edge and the second edge are close to or overlap. S3. Weld the first edge and the second edge together to obtain a three-way catalytic cone.
[0009] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology. In step S1, the sheet material is subjected to surface molding to obtain the molded blank. During surface molding, the material edge of the molded blank is also cut out. Surface molding utilizes a surface molding die, which includes: The bottom mold and the top mold are used to form a surface. The bottom mold is larger than the surrounding area of the molded blank. The bottom mold or the top mold has a circumferential cutting edge. The cutting edge is located around the top mold and is used to cut out the edge of the molded blank.
[0010] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology, wherein step S1 includes: S11, the sheet metal is subjected to surface molding to obtain a pre-molding blank, the pre-molding blank has a protrusion and side wings connected to both sides of the protrusion, and the two side wings have a first joint edge and a second joint edge; S12. Push the two side wings to flip to obtain the molded blank, the molded blank having the protrusion and the side wings.
[0011] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology, wherein the material edge includes a first connecting edge and a second connecting edge, and also includes a first opening edge and a second opening edge. The first connecting edge, the first opening edge, the second connecting edge and the second opening edge are connected end to end in sequence. The first opening edge is used to enclose a first interface, and the second opening edge is used to enclose a second interface.
[0012] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology, wherein the bottom mold for forming the surface has a raised forming part, the top mold for forming the surface has a recessed forming part, the raised forming part has a through part, and the through part extends through the molded blank to the outside of the second opening edge.
[0013] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology. In step S2, a cone forming mold is used during cone forming molding. The cone forming mold includes a cone forming bottom mold, a cone forming core mold, and a cone forming side mold. One end of the cone forming bottom mold and the cone forming side mold forms a forming opening, which is used to form the first interface. The other end of the cone forming bottom mold and the cone forming side mold is used to form the second interface.
[0014] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology, wherein step S2 includes: S21. Place the protrusion of the molded blank into the conical bottom mold; S22. Push the conical core mold into the molding blank; S23. The conical side mold pushes the two side wings until the first joint and the second joint are close to or overlap.
[0015] For example, at least one embodiment of this disclosure provides a three-way catalytic cone and its processing technology. In step S22, a positioning rod is used to limit the cone-shaped core mold, and the positioning rod passes through the forming opening.
[0016] The present invention provides a three-way catalytic cone and its processing technology, which requires only one outer wall welding, significantly reducing the number of welding steps. The reduction in the number of welding operations means fewer positioning and clamping operations during the welding process, thereby saving welding time and improving overall processing efficiency. Attached Figure Description
[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0018] Figure 1 This is a schematic diagram of the structure of a three-way catalytic cone in the prior art; Figure 2 This is a schematic diagram of the structure of the three-way catalytic cone provided in an embodiment of the present invention; Figure 3 This is an exploded structural diagram of the cutting mold in an embodiment of the present invention; Figure 4 This is an exploded structural diagram of the surface molding die in an embodiment of the present invention; Figure 5 This is an exploded structural diagram of the cone-forming molding die in an embodiment of the present invention; Figure 6This is an exploded structural diagram of the conical molding die from another perspective in an embodiment of the present invention; In the figure: main body 100, first interface 110, second interface 120, first joint 130, second joint 140, first opening edge 150, second opening edge 160, surface forming bottom mold 200, raised forming part 210, through part 211, surface forming top mold 300, trimming part 310, recessed forming part 320, protrusion 410, side wing 420, conical bottom mold 500, limiting surface 510, conical core mold 600, conical side mold 700, forming opening 800, positioning rod 900. Detailed Implementation
[0019] The specific embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit this disclosure. For ease of understanding, the English abbreviations and related technical terms involved in the embodiments of this disclosure will be explained and described below.
[0020] It should be understood that the described embodiments are merely some, not all, of the embodiments disclosed herein. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.
[0021] The terminology used in the embodiments of this disclosure is for the purpose of describing particular embodiments only and is not intended to be limiting of this disclosure. The singular forms “a,” “the,” and “the” as used in the embodiments of this disclosure and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise.
[0022] It should be understood that the term "and / or" used in this article is merely a way of describing the logical relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this article generally indicates that the preceding and following related objects have an "or" relationship.
[0023] Depending on the context, the word "if" as used here can be interpreted as "when" or "when" or "in response to determination" or "in response to detection." Similarly, depending on the context, the phrase "if determination" or "if detection (of the stated condition or event)" can be interpreted as "when determination" or "in response to determination" or "when detection (of the stated condition or event)" or "in response to detection (of the stated condition or event)."
[0024] It should be understood that the terms "first," "second," etc., used in this disclosure are for distinguishing purposes only and should not be construed as indicating or implying relative importance or order.
[0025] In the description of this disclosure, the terms “center,” “upper,” “lower,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and should not be construed as a limitation of this disclosure.
[0026] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, for example, they can refer to fixed connections, detachable connections, or mating connections or links; those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances.
[0027] like Figure 2 The diagram illustrates a three-way catalytic cone according to an embodiment of the present invention, comprising a main body 100. The main body 100 is a conical annular shape, with a first interface 110 at one end and a second interface 120 at the other end. The first interface 110 is larger than the second interface 120. The main body 100 is molded from a plate. One side of the plate has a first edge 130, and the other side has a second edge 140. The first edge 130 and the second edge 140 are welded together. The first edge 130 extends from the first interface 110 to the second interface 120. The annular shape does not necessarily have to be a regular ring; it can be an irregular ring or an irregular cylinder, as long as it meets the requirements of the three-way catalytic cone.
[0028] In some examples, the first joint 130 is the shortest distance along the cylinder wall of the main body 100 from the first interface 110 to the second interface 120. The distance between the first joint 130 and the second joint 140 is greatly reduced, and the required strength can be met by welding only the outer wall, without the need to weld both the outer and inner walls.
[0029] For example, the main body 100 of the three-way catalytic converter is designed as a conical annular shape, which meets the requirements of airflow guidance and catalytic reaction inside the three-way catalytic converter. The first interface 110 at one end is larger than the second interface 120 at the other end, forming a gradually changing channel, which helps to achieve reasonable changes in flow rate and pressure when the gas passes through the three-way catalytic converter, thereby improving the efficiency of the catalytic reaction. The main body 100 is molded from a plate. Compared with the traditional method of dividing the whole into two halves and molding them separately, this molding method reduces cumulative errors and improves product precision.
[0030] A first edge 130 is provided on one side of the plate, and a second edge 140 is provided on the other side. The first edge 130 and the second edge 140 are connected by welding. The first edge 130 extends from the first interface 110 to the second interface 120, and the first edge 130 is the shortest distance along the main body 100 cylinder wall from the first interface 110 to the second interface 120. This design greatly reduces the distance between the first edge 130 and the second edge 140. Under the premise of ensuring structural strength, only the outer wall welding is required to meet the usage requirements, eliminating the need for welding on both the inner and outer walls as in traditional methods, thus simplifying the welding process.
[0031] Traditionally, the three-way catalytic converter cone is divided into two halves and molded separately, requiring a mold for each molding process, which is cumbersome. This design, however, uses a single molding process, requiring only one molding operation, significantly reducing molding time and preparation work, and improving molding efficiency.
[0032] Traditional methods require four welding steps, while this design only requires one outer wall weld, significantly reducing the number of welding processes. This reduction in welding steps means fewer positioning and clamping operations during the welding process, thus saving welding time and improving overall processing efficiency.
[0033] Traditional two-stage molding increases the possibility of accumulated errors, affecting product precision. This design, through single-stage molding, reduces accumulated errors, better ensuring dimensional accuracy and shape consistency, and improving product quality.
[0034] Thermal deformation during welding is a significant factor affecting product quality. This design reduces the number of welding operations, thereby minimizing the impact of welding thermal deformation on the product. This allows the product to maintain good shape and dimensional stability after welding, further improving product quality.
[0035] The simplified molding and welding processes mean less manpower and material investment is required. This reduces the number of mold preparations, the usage time of welding equipment, and the workload of operators, thereby lowering production costs.
[0036] Increased processing efficiency allows for the production of more products per unit of time, reducing the fixed costs allocated to each product and further lowering production costs.
[0037] This embodiment also proposes a three-way catalytic cone and its processing technology, including the following steps: S1. The sheet metal is processed to obtain a molding blank. S11. Obtain the blank before molding by surface molding. Preparation: First, based on the product design of the three-way catalytic converter cone, use, for example... Figure 3The cutting die shown cuts the sheet material into its approximate shape. Select a suitable sheet material whose material meets the performance requirements of the three-way catalytic converter cone in terms of high temperature resistance and corrosion resistance. Prepare as follows... Figure 4 The surface molding die shown includes a surface molding bottom die 200 and a surface molding top die 300. The perimeter of the surface molding bottom die 200 is larger than the perimeter of the molding blank, and the perimeter of the surface molding top die 300 is provided with a circumferentially shaped cutting edge 310.
[0038] The prepared sheet material is placed on the bottom die 200, and the press is started to press down the top die 300. Under the pressure, the sheet material gradually deforms, and the cutting edge 310 of the top die 300 cuts the edge of the sheet material. At the same time, the sheet material is molded into a pre-molding blank with a protrusion 410 and side wings 420 connected to both sides of the protrusion 410.
[0039] S12, Push the two side wings to flip and obtain the molded blank. After the preform is formed before molding, the two side wings 420 are pushed to flip around the protrusion 410. During this process, it is important to control the angle and force of the flipping to ensure that the two side wings 420 accurately reach the predetermined position, thus obtaining the final molded preform. This molded preform still retains the protrusion 410 and the side wings 420, and the two side wings 420 each have a first edge 130 and a second edge 140.
[0040] S2. The die blank is cone-shaped and molded. S21. Place the protrusion of the molding blank into the conical bottom mold. like Figures 5-6 As shown, prepare a conical molding die, which includes a conical bottom die 500, a conical core die 600, and a conical side die 700. Accurately place the protrusion 410 of the molding blank obtained in step S1 into the corresponding position of the conical bottom die 500. This step requires precise positioning to ensure the accurate positioning of the blank during subsequent molding processes and to guarantee the dimensional accuracy of the formed three-way catalytic converter cone.
[0041] S22. Push the conical core mold into the molding blank. After the conical bottom mold 500 is placed into the protrusion 410 of the molding blank, the conical core mold 600 is slowly pushed into the molding blank along a specific direction. The function of the conical core mold 600 is to support the molding blank internally and assist it in forming a conical structure. During the pushing process, care should be taken to control the depth and perpendicularity of the conical core mold 600 to ensure that the molding blank can be evenly stressed, thereby forming a regularly shaped cone.
[0042] S23. The conical side mold pushes the two side wings until the first and second joints are close to or overlap. After the conical core mold 600 is in place, the conical side mold 700 begins to move. The conical side mold 700 pushes the two side wings 420 of the molded blank from both sides, gradually causing the side wings 420 to bend and deform around the conical core mold 600. As the conical side mold 700 continues to push, the first joint 130 and the second joint 140 on the two side wings 420 gradually approach or overlap, ultimately forming a structure close to the shape of a three-way catalytic converter cone. During this process, the thrust, pushing speed, and pushing distance of the conical side mold 700 must be precisely controlled to ensure that the first joint 130 and the second joint 140 can accurately approach or overlap, while ensuring that the cone's taper and overall shape meet the design requirements.
[0043] S3. Weld the first joint 130 and the second joint 140 to obtain the three-way catalytic cone. After the first edge 130 and the second edge 140 approach or overlap, the welding area is cleaned to remove surface oil, impurities, etc., to ensure welding quality. A suitable welding process, such as argon arc welding or laser welding, is selected, and the corresponding welding equipment and materials are prepared.
[0044] The function of the bottom die 200 is to cooperate with the top die 300 to mold the sheet material. Its perimeter is larger than that of the blank, providing sufficient space for deformation of the sheet material during molding and ensuring the complete forming of the blank. Simultaneously, it works in conjunction with the top die 300 to guarantee the shape accuracy of the blank before molding.
[0045] The top die 300 has a cutting edge 310. During the molding process, the cutting edge 310 cuts the edge of the sheet metal as the top die 300 is pressed down, cutting out the edge of the molding blank to conform to the design dimensions. At the same time, the top die 300 and the bottom die 200 work together to apply pressure to the sheet metal, forming a pre-molding blank with a protrusion 410 and side wings 420.
[0046] The conical bottom mold 500 is used to place the protrusion 410 of the molding blank, providing bottom support for the molding blank during the conical process. It and the conical side mold 700 together form a forming opening 800 at one end, which is used to form the first interface 110 of the three-way catalytic converter cone. The other end works together with the conical side mold 700 to form the second interface 120, playing an important role in positioning and forming the overall shape and dimensional accuracy of the three-way catalytic converter cone.
[0047] The conical core mold 600 is inserted into the molded blank during the conical molding process, providing internal support and assisting in the formation of the conical structure. This ensures that the molded blank is subjected to uniform force during the conical process, preventing excessive local deformation or irregular shapes, and helps improve the shape accuracy and internal structural stability of the three-way catalytic converter cone.
[0048] The conical side mold 700 pushes the side wings 420 of the molding blank from both sides, causing it to bend and deform around the conical core mold 600, ultimately bringing the first edge 130 and the second edge 140 closer together or overlapping. The precise control of the thrust, pushing speed, and pushing distance of the conical side mold 700 directly affects the molding quality of the three-way catalytic converter cone, including the taper and the degree of fit of the edges.
[0049] Compared to the traditional method of molding and welding two halves of the three-way catalytic converter cone separately, this process reduces the cumulative errors caused by multiple molding processes by using a single surface molding and a single cone molding. Each molding step allows for more precise control of dimensions and shape, thereby improving the overall processing accuracy of the three-way catalytic converter cone.
[0050] The cutting edge 310 of the surface molding die can accurately cut the edge of the molding blank, ensuring the dimensional accuracy of the blank before molding. The precise fit between the various parts of the cone molding die, such as the cone bottom die 500, the cone core die 600 and the cone side die 700, ensures the shape accuracy and edge fitting accuracy of the three-way catalytic converter cone during the cone forming process, further improving the processing accuracy of the product.
[0051] This processing technology eliminates the traditional, complex process of dividing the whole into two halves, processing them separately, and then welding them together. Through optimized molding and welding steps, the production process is greatly simplified. This reduces the number of mold preparations and welding operations, shortens the production cycle, and improves production efficiency.
[0052] In both planar and conical molding processes, the design and operation of the molds make the molding process more efficient. For example, planar molding molds perform edge trimming during molding, reducing additional processing steps; conical molding molds, through the coordinated action of their various parts, can quickly and accurately form the molded blank into a three-way catalytic cone, further improving production efficiency.
[0053] Because the process is simplified, the types and frequency of mold use are reduced, thus lowering the costs of mold manufacturing, maintenance, and replacement. For example, the traditional method requires two sets of half-shell molding dies, while this process only requires one set of surface molding die and one set of cone molding die, effectively saving on mold costs.
[0054] Streamlined processes mean less manpower required, and shorter production cycles also reduce time costs. The reduction in steps and time required from sheet material processing to final product shaping lowers production costs.
[0055] In some examples, the material edge includes a first connecting edge 130 and a second connecting edge 140, as well as a first opening edge 150 and a second opening edge 160. The first connecting edge 130, the first opening edge 150, the second connecting edge 140 and the second opening edge 160 are connected end to end in sequence. The first opening edge 150 is used to enclose the first interface 110, and the second opening edge 160 is used to enclose the second interface 120.
[0056] The bottom mold 200 has a raised forming part 210, the top mold 300 has a recessed forming part 320, the raised forming part 210 has a through part 211, the through part 211 extends through the molded blank to the outside of the second edge 160.
[0057] For example, the material edge includes a first connecting edge 130, a second connecting edge 140, a first opening edge 150, and a second opening edge 160. These four edges are connected end to end to form the edge structure of the molded blank. Among them, the first connecting edge 130 and the second connecting edge 140 serve to connect the two sides of the main body in the subsequent welding process, while the first opening edge 150 and the second opening edge 160 are used to form the first interface 110 and the second interface 120 of the three-way catalytic converter cone, respectively. This design allows for more accurate shaping of the overall shape and interface parts of the three-way catalytic converter cone during the molding process by precisely controlling the material edge, laying a good foundation for the subsequent cone molding and welding processes.
[0058] The dimensions, shape, and positional accuracy of the first edge 150 and the second edge 160 directly affect the molding quality of the first interface 110 and the second interface 120 of the three-way catalytic converter cone. During the surface molding process, the cutting part 310 cuts the sheet material, determining the initial shape and dimensions of the first edge 150 and the second edge 160. In the subsequent cone molding process, related components of the cone mold, such as the cone bottom mold 500 and the cone side mold 700, interact with the first edge 150 and the second edge 160 to further shape them into interface shapes that meet the design requirements. For example, the degree of fit between the cone bottom mold 500 and the first edge 150 and the second edge 160, as well as the direction and magnitude of the pressure applied by the cone side mold 700, will affect parameters such as the taper and flatness of the interface.
[0059] The positional and shape accuracy of the first edge 130 and the second edge 140 are crucial for subsequent welding processes. During the surface molding process, the trimmed portion 310 ensures the cutting accuracy of the first edge 130 and the second edge 140, allowing them to accurately approach or overlap after cone molding, facilitating welding. Accurate edge positioning helps improve welding quality, reduce welding deformation, and ensure the overall structural strength of the three-way catalytic converter cone.
[0060] The raised forming portion 210 on the bottom mold 200 plays a forming role during the molding process. It cooperates with the recessed forming portion 320 of the top mold 300 to apply pressure to the sheet metal, causing plastic deformation between the two to form a specific shape of the molded blank. The shape and size of the raised forming portion 210 match the parts of the molded blank that need to be formed. For example, it can shape the internal structure of the molded blank or specific raised parts to ensure the shape accuracy and structural integrity of the molded blank.
[0061] The recessed forming part 320 of the top die 300 corresponds to the raised forming part 210, and together they mold the sheet material. The presence of the recessed forming part 320 allows the sheet material to better fill the space around the raised forming part 210 during the molding process, further ensuring the molding quality of the molded blank. At the same time, the recessed forming part 320 and the trimming part 310 work together to cut the material edge during molding, ensuring the precision of the material edge and the overall dimensional accuracy of the molded blank.
[0062] The protruding portion 211 of the protruding forming portion 210 extends through the molding blank to the outside of the second opening edge 160. During the molding process, the protruding portion 211 can serve as a positioning reference, helping to determine the position of the molding blank on the forming bottom mold 200 and improving the accuracy of molding. Simultaneously, the protruding portion 211 assists in the forming of the second opening edge 160. It can apply a certain pressure to the edge portion of the second opening edge 160 during the molding process, allowing it to be better formed into the required shape and ensuring the dimensional accuracy and shape regularity of the second interface 120. For example, during the molding process, the protruding portion 211 can prevent the second opening edge 160 from excessively deforming or wrinkling under pressure, ensuring that it can accurately form the second interface 120 that meets the design requirements.
[0063] During the surface molding process, the surface-forming bottom mold 200 and surface-forming top mold 300 are installed on the press and adjusted to ensure that all parameters of the mold are normal. According to the design requirements of the three-way catalytic converter cone, the pre-cut sheet material is placed on the surface-forming bottom mold 200, so that the sheet material covers the raised forming part 210. At this time, attention should be paid to the placement position of the sheet material to ensure that the protruding part 211 accurately corresponds to the part on the sheet material related to the second edge 160.
[0064] During molding and trimming, the press is started, and the top die 300 presses down. The recessed forming part 320 and the raised forming part 210 jointly apply pressure to the sheet material, causing it to gradually deform. Simultaneously, the trimming part 310 cuts the edges of the sheet material, forming a first edge 130, a second edge 140, a first edge 150, and a second edge 160. During molding, the protruding part 211 extends through the sheet material to the outside of the second edge 160, providing positioning and assistance for its formation. By precisely controlling molding parameters such as pressure, speed, and time, the shape, size, and edge precision of the molded blank meet design requirements, completing the pre-molding blank forming process.
[0065] After the preform is formed before molding, the two side wings 420 are pushed to flip it over according to process step S12 to obtain the molded preform. In this process, since the accuracy of the material edge has been guaranteed in the surface molding stage, the flipping of the side wings 420 can reach the predetermined position more accurately, providing a good foundation for the subsequent conical molding.
[0066] Entering the conical molding stage, according to process step S2, the protrusion 410 of the molding blank is placed into the conical bottom mold 500, and the conical core mold 600 is inserted. Then, the conical side mold 700 pushes the two side wings 420 until the first joint 130 and the second joint 140 approach or overlap. Since the first edge 150 and the second edge 160 have already achieved high precision in the surface molding stage, the conical mold can more accurately mold the first interface 110 and the second interface 120. Finally, the first joint 130 and the second joint 140 are welded to obtain the three-way catalytic cone. During the welding process, because the joint is accurately positioned in the surface molding stage, the welding quality is more easily guaranteed, reducing welding defects and deformation caused by inaccurate jointing.
[0067] Through precise cutting and design of the material edges, the first edge 150 and the second edge 160 can accurately surround the first interface 110 and the second interface 120, improving the dimensional accuracy and shape regularity of the interface area. The high-precision cutting of the first joint edge 130 and the second joint edge 140 enables more accurate butt welding, reduces welding errors, and further ensures the overall precision of the product.
[0068] The synergistic effect of the protruding forming part 210, the recessed forming part 320, and the through-hole part 211 enables the molding blank to be formed more accurately during the surface molding stage. The positioning and auxiliary forming function of the through-hole part 211 for the second edge 160 effectively improves the forming accuracy of the second interface 120, thereby improving the processing accuracy of the entire three-way catalytic cone.
[0069] The well-designed material edge facilitates smoother subsequent conical molding and welding processes. Accurate material edge dimensions and shapes reduce the workload of adjusting interfaces and joints during conical molding, lowering the risk of quality problems caused by improper adjustments. Simultaneously, precise joint positioning improves welding success rates, reduces product scrap due to welding issues, and enhances the stability of the production process.
[0070] The cooperation between the raised forming part 210 and the recessed forming part 320 in the surface molding die, as well as the positioning and auxiliary forming functions of the through part 211, make the molding process more stable. During the molding process, the deformation of the sheet metal can be better controlled, reducing molding defects caused by poor fit between the die and the sheet metal, ensuring the stability of the quality of the molded blank, and thus improving the stability of the entire production process.
[0071] In a single molding process, the surface molding die not only forms the molding blank but also cuts the material edge through the trimming part 310, reducing additional processing steps. At the same time, the synergistic effect of the raised forming part 210, the recessed forming part 320, and the through part 211 makes the molding process more efficient, shortens the molding time of a single product, and improves production efficiency.
[0072] Thanks to improved material edge precision and optimized mold structure, adjustments and repairs to the product are reduced in subsequent conical molding and welding processes. For example, there is no need to spend a lot of time trimming interfaces and joints, thus shortening the overall production cycle and further improving production efficiency.
[0073] In some examples, in step S22, the conical core mold 600 is limited by the positioning rod 900, which passes through the forming opening 800.
[0074] The positioning rod 900 is a component used to limit the conical core mold 600 during the cone molding process of the three-way catalytic converter. It has a certain length and diameter, and its diameter needs to be adapted to the size of the forming orifice 800 so that it can pass smoothly through the forming orifice 800.
[0075] In step S22, when the conical core mold 600 is pushed into the molding blank, the positioning rod 900 passes through the forming opening 800 formed by the conical bottom mold 500 and one end of the conical side mold 700. One end of the positioning rod 900 engages with a specific limiting structure on the conical core mold 600, such as a limiting hole or a limiting groove, while the other end, through its relative positional relationship with the surrounding structure of the forming opening 800, restricts the direction and depth of movement of the conical core mold 600 during the molding process. This ensures that the conical core mold 600 is accurately positioned within the predetermined location inside the molding blank, thereby guaranteeing that the molding blank can deform uniformly around the conical core mold 600 during the conical molding process, ultimately forming a three-way catalytic cone with high shape accuracy.
[0076] Before the cone molding process, the cone-shaped bottom mold 500, cone-shaped core mold 600, cone-shaped side mold 700, and positioning rod 900 are cleaned and inspected to ensure that all components are free of damage and impurities. According to the design requirements of the three-way catalytic converter cone, the positioning rod 900 is installed in the appropriate position so that it can accurately pass through the molding opening 800.
[0077] The positioning rod 900 precisely limits the position of the conical core mold 600, ensuring that the conical core mold 600 does not shift or tilt during the molding process. This makes the deformation of the molded blank around the conical core mold 600 more uniform, thereby improving the shape accuracy of the three-way catalytic converter cone, especially in key indicators such as taper and concentricity. For example, the positioning rod 900 effectively reduces the unevenness of the inner wall of the three-way catalytic converter cone caused by positional deviations of the conical core mold 600, improving the overall precision of the product.
[0078] Due to the precise positioning of the conical core mold 600, the forming accuracy of the first interface 110 and the second interface 120 is also improved during the conical molding process. The relative positions between the conical core mold 600, the conical bottom mold 500, and the conical side mold 700 are more stable, which helps to ensure the dimensional accuracy and shape regularity of the interface parts and reduces problems such as subsequent assembly difficulties caused by interface accuracy issues.
[0079] The use of positioning rod 900 reduces uncertainties in the conical molding process. Without the positioning rod 900 for restraint, the conical mandrel 600 may shift position during molding due to uneven stress, affecting product quality. The positioning rod 900's restraining function makes the conical molding process more stable, reducing product scrap or rework caused by mandrel 600 positional changes, and improving the stability and reliability of the production process.
[0080] The positioning rod 900 provides operators with a clear positioning reference, making the installation and adjustment of the conical mandrel 600 easier. Operators only need to accurately align the positioning rod 900 with the limiting structure of the conical mandrel 600, and observe the relative position of the positioning rod 900 and the forming opening 800 to quickly and accurately complete the installation and positioning of the conical mandrel 600, reducing operational difficulty and minimizing product quality fluctuations caused by differences in operator skills.
[0081] During the conical molding process, the positioning rod 900 can quickly and accurately limit the position of the conical mandrel 600, reducing the adjustment time for the position of the conical mandrel 600. Compared to the need for repeated adjustments to ensure the accuracy of the conical mandrel 600 without the positioning rod 900, the use of the positioning rod 900 greatly shortens the preparation time before conical molding and improves production efficiency.
[0082] The positioning rod 900 enhances production stability and reduces production interruptions caused by product quality issues. The need to pause production for adjustments due to inaccurate positioning of the conical mandrel 600 is reduced, allowing for more continuous production and further improving efficiency.
[0083] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A three-way catalytic cone, characterized in that, Includes a main body (100), which is a conical ring-shaped cylinder with a first interface (110) at one end and a second interface (120) at the other end. The first interface (110) is larger than the second interface (120). The main body (100) is molded from a plate. One side of the plate has a first edge (130) and the other side has a second edge (140). The first edge (130) and the second edge (140) are welded together. The first edge (130) extends from the first interface (110) to the second interface (120).
2. A three-way catalytic cone according to claim 1, characterized in that, The first joint (130) is the shortest distance along the cylinder wall of the main body (100) from the first interface (110) to the second interface (120).
3. A three-way catalytic cone and its processing technology, used to process the three-way catalytic cone according to any one of claims 1-2, characterized in that, Includes the following steps: S1. The sheet metal is processed to obtain a molding blank, and the molding blank has a first joint (130) and a second joint (140) on both sides. S2. The molding blank is cone-shaped and molded so that the first joint (130) and the second joint (140) are close to or overlap. S3. Weld the first edge (130) and the second edge (140) to obtain a three-way catalytic cone.
4. A three-way catalytic cone and its processing technology according to claim 3, characterized in that, In step S1, the sheet metal is subjected to surface molding to obtain the molded blank. During surface molding, the edges of the molded blank are also cut out. Surface molding is performed using a surface molding die, which includes: The bottom mold (200) and the top mold (300) are surfaced. The bottom mold (200) is larger than the periphery of the molded blank. The bottom mold (200) or the top mold (300) has a circumferentially shaped cutting edge (310) located around the top mold (300). The cutting edge (310) is used to cut out the edge of the molded blank.
5. A three-way catalytic cone and its processing technology according to claim 4, characterized in that, Step S1 includes: S11, the sheet metal is subjected to surface molding to obtain a pre-molding blank. The pre-molding blank has a protrusion (410) and side wings (420) connected to both sides of the protrusion (410). The two side wings (420) have a first joint edge (130) and a second joint edge (140). S12. Push the two side wings (420) to flip to obtain the molding blank, the molding blank having the protrusion (410) and the side wings (420).
6. A three-way catalytic cone and its processing technology according to claim 4, characterized in that, The material edge includes the first connecting edge (130) and the second connecting edge (140), and also includes the first opening edge (150) and the second opening edge (160). The first connecting edge (130), the first opening edge (150), the second connecting edge (140) and the second opening edge (160) are connected end to end in sequence. The first opening edge (150) is used to enclose the first interface (110), and the second opening edge (160) is used to enclose the second interface (120).
7. A three-way catalytic cone and its processing technology according to claim 6, characterized in that, The bottom mold (200) has a raised forming part (210), the top mold (300) has a recessed forming part (320), the raised forming part (210) has a protruding part (211), the protruding part (211) extends through the molded blank to the outside of the second opening edge (160).
8. A three-way catalytic cone and its processing technology according to claim 5, characterized in that, In step S2, a conical mold is used during the conical molding process. The conical mold includes a conical bottom mold (500), a conical core mold (600), and a conical side mold (700). One end of the conical bottom mold (500) and the conical side mold (700) forms a forming opening (800), which is used to press out the first interface (110). The other end of the conical bottom mold (500) and the conical side mold (700) is used to press out the second interface (120).
9. A three-way catalytic cone and its processing technology according to claim 8, characterized in that, Step S2 includes: S21. Place the protrusion (410) of the molded blank into the conical bottom mold (500). S22. Push the conical core mold (600) into the molding blank; S23, the conical side mold (700) pushes the two side wings (420) until the first joint (130) and the second joint (140) approach or overlap.
10. A three-way catalytic cone and its processing technology according to claim 8, characterized in that, In step S22, the conical core mold (600) is limited by a positioning rod (900), which passes through the forming opening (800).