System and method for preparing embossed graphite-based web

Abstract

Systems, methods, and products are described that involve a set of calender rollers positioned adjacent to a set of embossing or cutting or combining rollers, but without a heating unit disposed therebetween. The produced embossed or cut graphite-based webs with bipolar plate structures can be manufactured at reduced cost and with improved quality.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 442,895, filed February 2, 2023, which is incorporated herein by reference in its entirety. Background Art

[0002] Bipolar plates are important components of fuel cell cells that distribute fuel and air, conduct electrical current, and remove heat generated in the reaction zone of the cell. Bipolar plates are also useful in other applications, such as when used as separators in redox flow batteries.

[0003] Embossing and cutting of graphite-based fiber webs are traditionally performed as separate, independent processes from the multi-roll calendering (MRC) process.The fiber web is cooled after the calendering process and then heated before embossing and / or cutting.

[0004] Although the two-step process has achieved commercial success to date, there remains a need for improved and more efficient methods for preparing embossed and cut graphite-based fiber webs having bipolar plate structures. Summary of the Invention

[0005] In some aspects, the technology described herein relates to a multi-roller method for preparing a treated fiber web having a bipolar plate structure, the method comprising: providing a multi-roller calendering system, the multi-roller calendering system comprising one or more calendering rolls and one or more processing rolls, wherein the system does not include any heating unit arranged between the calendering rolls and the embossing rolls; outputting an untreated fiber web from the calendering rolls; and inputting the untreated fiber web into the processing rolls to prepare the treated fiber web having a bipolar plate structure; wherein the one or more processing rolls comprise one or more cutting rolls, one or more embossing rolls and / or one or more combination rolls.

[0006] In some aspects, the technology described herein relates to a multi-roll system for preparing a treated fiber web having a bipolar plate structure, the system comprising: one or more calendering rolls and one or more treatment rolls; wherein: the system does not include any heating unit arranged between the calendering rolls and the treatment rolls, and the one or more treatment rolls include one or more cutting rolls, one or more embossing rolls and / or one or more combination rolls.

[0007] In some aspects, the technology described herein relates to a treated graphite-based fiber web having a bipolar plate structure prepared by a multi-roller method, the method comprising: providing a system comprising one or more calendering rollers and one or more processing rollers; wherein the system does not include any heating unit arranged between the calendering rollers and the processing rollers; outputting an untreated graphite-based fiber web from the calendering rollers; and inputting the untreated graphite-based fiber web into the processing rollers to prepare the treated graphite-based fiber web having a bipolar plate structure; wherein the one or more processing rollers comprise one or more cutting rollers, one or more embossing rollers and / or one or more combination rollers. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The various aspects, features, benefits and advantages of the embodiments described herein will become apparent when taken in conjunction with the following description, appended claims and accompanying drawings, in which: Figure 1 A system comprising seven calendering rollers 100 and two embossing rollers 200 is shown, wherein no heating unit 300 is positioned between the calendering rollers and the embossing rollers. The arrows and dark curved arcs show the path of the material through the rollers of the system.

[0009] Figure 2 A system with different zones is shown. In order, the system has a melting zone 400, a kneading zone 500, a cooling / tempering zone 600 and an embossing zone 700.

[0010] Figure 3 A system is shown with a heating unit 300 positioned between the calendering roll 100 and the embossing roll 200 . DETAILED DESCRIPTION

[0011] The present disclosure is not limited to the particular systems, devices, and methods described, as these may vary. The terminology used in the description is for the purpose of describing particular versions or embodiments only and is not intended to limit the scope.

[0012] "Calendering rolls" refer to rolls that apply one or more of heat, pressure, shear, or other physical conditions to the graphite film web. A system may have one or more calendering rolls or two or more calendering rolls. Calendering rolls are typically configured in pairs and meter the material to a predetermined thickness or density by passing it through a controlled gap.

[0013] "Heating unit" refers to a device that increases the temperature of the untreated web before it contacts the treatment rolls.

[0014] system In one example of the present technology, a system is described that can be used to prepare a treated web having a bipolar plate structure. In some examples, the treated web having a bipolar plate structure is a treated graphite-based web having a bipolar plate structure made from a graphite web / membrane. In some embodiments, the treated web includes one or more embossed bipolar plate structures. In one embodiment, the treated web includes one or more cut bipolar plate structures. The system may include one or more calendering rollers and one or more processing rollers. The system does not include any heating unit disposed between the calendering rollers and the processing rollers. In some embodiments, the one or more processing rollers are positioned adjacent to the one or more calendering rollers. The system is configured so that the output of the calendering roller (untreated web) becomes the input of the processing roller without being exposed to or contacting a heating unit after the calendering roller but before the processing roller. The system is not configured to heat the output of the calendering roller before it becomes the input of the processing roller. The output of the processing roller is a treated web having at least one bipolar plate structure. In some embodiments, the one or more processing rollers include one or more embossing rollers. In some embodiments, the one or more processing rollers include one or more cutting rollers. In still further embodiments, the processing roll comprises one or more rolls that cut and emboss the web during operation as the roll contacts the web. Such rolls that both cut and emboss the web are referred to as combination rolls.

[0015] In some embodiments, the one or more embossing rollers include at least one embossing roller having convex embossing features and at least one embossing roller having concave embossing features. In some embodiments, the convex embossing features and the concave embossing features are configured to align when the fiber web passes between the embossing rollers.

[0016] The system can be configured so that the temperature of the output of the calendering roll is greater than or equal to the temperature of the input of the process roll. The system can be configured so that the temperature of the output of the calendering roll does not drop below the temperature of the input of the process roll. In some examples, the system is configured so that the output of the calendering roll continues directly as the input of the process roll without any additional processing.

[0017] The number of calendering rollers and process rollers can generally be any number. The number of calendering rollers and process rollers can generally be any positive, non-zero integer. The number of calendering rollers and process rollers can be the same or different. For example, the number of calendering rollers can be two or more, such as two, three, four, five, six, seven, eight, or more calendering rollers. For example, the number of process rollers can be two or more, such as two, three, four, five, six, seven, eight, or more process rollers. In some specific examples, the number of process rollers can be two (a pair of process rollers).

[0018] In some embodiments, the one or more processing rollers include one or more embossing rollers. The number of embossing rollers can generally be any number. The number of embossing rollers can generally be any positive non-zero integer. The number of embossing rollers can be the same as or different from the number of calendering rollers. For example, the number of embossing rollers can be 2 or more, such as 2, 3, 4, 5, 6, 7, 8 or more embossing rollers. In some specific examples, the number of embossing rollers can be 2 (a pair of embossing rollers).

[0019] In some embodiments, the one or more processing rollers include one or more cutting rollers. The number of cutting rollers can generally be any number. The number of cutting rollers can generally be any positive non-zero integer. The number of cutting rollers can be the same as or different from the number of calendering rollers. For example, the number of cutting rollers can be 2 or more, such as 2, 3, 4, 5, 6, 7, 8 or more cutting rollers. In some specific examples, the number of cutting rollers can be 2 (a pair of cutting rollers).

[0020] In some embodiments, the one or more process rollers include one or more combination rollers. The number of combination rollers can generally be any number. The number of combination rollers can generally be any positive non-zero integer. The number of combination rollers can be the same as or different from the number of calendering rollers. For example, the number of combination rollers can be 2 or more, such as 2, 3, 4, 5, 6, 7, 8 or more combination rollers. In some specific examples, the number of combination rollers can be 2 (a pair of combination rollers).

[0021] In some embodiments, the one or more cutting rolls or combination rolls include at least one cutting roll or combination roll having a convex cutting feature and at least one cutting roll or combination roll having a concave cutting feature. In some embodiments, the convex cutting feature and the concave cutting feature are configured to align as the web passes between the cutting rolls or combination rolls.

[0022] In some embodiments, the one or more process rollers include one or more cutting rollers and one or more embossing rollers. In some embodiments, the one or more cutting rollers are positioned before the one or more embossing rollers. In some embodiments, the system is configured such that the output of the one or more cutting rollers is the input of the one or more embossing rollers. In some embodiments, the one or more embossing rollers are positioned before the one or more cutting rollers. In some embodiments, the system is configured such that the output of the one or more embossing rollers is the input of the one or more cutting rollers. Similarly, one or more combination rollers may be positioned before, between, or after the cutting rollers or embossing rollers such that the output of one roller or group of rollers can be input to the next roller or group of rollers.

[0023] The calendering rolls can be organized into one or more sets or zones. For example, there may be a melting zone, a kneading zone, and a cooling / tempering zone. In a specific example, two calendering rolls may be in the melting zone, four calendering rolls may be in the kneading zone, and one calendering roll may be in the cooling / tempering zone. The zones can be arranged adjacent to each other so that the material is always in contact with at least one roll during the process.

[0024] Preparation method In another example of the present technology, a method for preparing a treated fiber web having a bipolar plate structure (such as a treated graphite-based fiber web having a bipolar plate structure) is described. The method may include: providing a system comprising one or more calendering rollers and one or more processing rollers; wherein the system does not include any heating unit disposed between the calendering rollers and the processing rollers; outputting an untreated fiber web from the calendering rollers; and inputting the untreated fiber web to the processing rollers to prepare a treated fiber web having at least one bipolar plate structure. In some embodiments, the one or more processing rollers are positioned adjacent to the one or more calendering rollers. In some embodiments, the one or more processing rollers include one or more embossing rollers. In some embodiments, the one or more processing rollers include one or more cutting rollers. In some embodiments, at least one bipolar structure includes at least one embossed bipolar structure. In some embodiments, at least one bipolar structure includes at least one cut bipolar structure.

[0025] In some embodiments, the one or more embossing rollers include at least one embossing roller having convex embossing features and at least one embossing roller having concave embossing features. In some embodiments, the method further comprises: aligning the convex embossing features with the concave embossing features. In some embodiments, the convex embossing features and the concave embossing features are aligned when the untreated fiber web is input between the embossing rollers. In some embodiments, the one or more embossing rollers are configured to output an embossed fiber web having at least one embossed bipolar plate structure.

[0026] In some embodiments, the system further comprises one or more cutting rollers, and the method further comprises inputting the embossed web to the cutting rollers to prepare a cut web. In some embodiments, the system further comprises one or more cutting rollers, and the method further comprises inputting the untreated web to the cutting rollers to prepare a cut web. In some embodiments, the one or more embossing rollers are configured to output a cut web having at least one cut bipolar plate structure. Similarly, one or more combination rollers may be disposed before, between, or after the cutting rollers or embossing rollers so that the output of one roller or a group of rollers can be input to the next roller or the next group of rollers.

[0027] In some embodiments, the one or more cutting rolls include at least one cutting roll or combination roll having a convex cutting feature and at least one cutting roll or combination roll having a concave cutting feature. In some embodiments, the method further comprises: aligning the convex cutting feature with the concave cutting feature. In some embodiments, the convex cutting feature and the concave cutting feature are aligned when the untreated fiber web is fed between the cutting rolls. In some embodiments, the method further comprises: aligning the convex cutting feature with the concave cutting feature when the embossed fiber web is fed between the cutting rolls or combination rolls.

[0028] In some examples, the temperature of the untreated web upon exiting the calender roll is substantially the same as the temperature of the untreated web upon entering the treatment roll. In other examples, the method may further include cooling the untreated web after exiting the calender roll and before entering the treatment roll. For example, the untreated web may be cooled to a desired input temperature for the treatment roll. In some embodiments, the treated web may be cooled after treatment. In some embodiments, the treated web may be cooled after embossing. In some embodiments, the treated web may be cooled after cutting.

[0029] Compared to systems with at least one heating unit between the calendering rolls and the processing rolls, the method can reduce energy use, capital expenditures, and operating expenses. Additionally, there is no need to wind and unwind the unprocessed material before processing. Compared to systems without a multi-roller arrangement, the method can reduce energy consumption because the material does not need to be reheated between rolling steps in a multi-roller arrangement.

[0030] The produced treated fiber web having at least one bipolar plate structure may be subjected to further processing, such as application of adhesive, winding, cutting, and the like.

[0031] The method may also include one or more additional upstream steps, such as, for example, contacting a raw material between a first roller and a second roller. The raw material may be in various physical forms, such as a powder or flakes. In some examples, the raw material is graphite powder or graphite flakes. The method may also include melting the raw material. The method may also include kneading the molten raw material to produce a homogeneous fibrous web. The method may also include cooling the homogeneous fibrous web to a temperature suitable for embossing. In some examples, the fibrous web is supported by at least one roller throughout the entire preparation process, from formation of the initial homogeneous fibrous web to processing. In these examples, no fibrous web handling is required between the various preparation steps.

[0032] product In other examples of the present technology, a treated graphite-based fiber web having at least one bipolar plate structure prepared by one or more of the above methods is described. In some embodiments, the treated graphite-based fiber web includes at least one embossed bipolar plate structure. In some embodiments, the treated graphite-based fiber web includes at least one cut bipolar plate structure. It is expected that the products produced by the described methods have superior quality and consistency compared to conventional embossed fiber webs. For example, the products are expected to have fewer defects per unit area and lower stress values.

[0033] Item 1. A multi-roller method for preparing an embossed fiber web having a bipolar plate structure, the method comprising: providing a system comprising one or more calendering rolls and one or more embossing rolls; wherein the system does not include any heating unit disposed between the calendering rolls and the embossing rolls; outputting an unembossed fiber web from the calendering rolls; and inputting the unembossed fiber web to the embossing rolls to prepare the embossed fiber web having a bipolar plate structure.

[0034] Clause 2. The method of Clause 1, excluding heating the unembossed web after it is output from the calendering roll and before it is input into the embossing roll.

[0035] Clause 3. The method of Clause 1, further comprising cooling the unembossed web after the unembossed web is output from the calendering roll and before the unembossed web is input into the embossing roll.

[0036] Clause 4. The method of Clause 1, wherein the non-embossed fiber web is a non-embossed graphite-based fiber web.

[0037] Clause 5. The method of Clause 1, wherein the embossed fiber web is an embossed graphite-based fiber web.

[0038] Item 6. A multi-roll system for preparing an embossed fiber web having a bipolar plate structure, the system comprising: one or more calendering rolls and one or more embossing rolls; wherein: the system does not include any heating unit disposed between the calendering rolls and the embossing rolls.

[0039] Clause 7. The system of Clause 6, configured such that the output of the calendering roll becomes the input of the embossing roll.

[0040] Clause 8. The system of Clause 6, configured such that the output of the calendering roll is an unembossed web.

[0041] Clause 9. The system of Clause 6, configured such that the output of the calendering roll is an unembossed graphite-based fiber web.

[0042] Clause 10. The system of Clause 6, configured such that the output of the embossing roller is an embossed fiber web having a bipolar plate structure.

[0043] Clause 11. The system of Clause 6, configured such that the output of the embossing roller is an embossed graphite-based fiber web having a bipolar plate structure.

[0044] Clause 12. The system of Clause 6, comprising two or more calendering rolls.

[0045] Clause 13. The system of clause 6, comprising 7 calendering rolls.

[0046] Clause 14. The system of Clause 6, comprising 2, 3, 4, 5, 6, 7 or 8 calendering rolls.

[0047] Clause 15. The system of Clause 6, comprising two or more embossing rollers.

[0048] Clause 16. The system of clause 6, comprising two embossing rollers.

[0049] Clause 17. The system of Clause 6, comprising 2, 3, 4, 5, 6, 7 or 8 embossing rollers.

[0050] Clause 17. The system of Clause 6, wherein the embossed fiber web having a bipolar plate structure is an embossed graphite-based fiber web having a bipolar plate structure.

[0051] Item 18. An embossed graphite-based fiber web having a bipolar plate structure prepared by a multi-roller method, the method comprising: providing a system comprising one or more calendering rollers and one or more embossing rollers; wherein the system does not include any heating unit arranged between the calendering rollers and the embossing rollers; outputting an unembossed graphite-based fiber web from the calendering rollers; and inputting the unembossed graphite-based fiber web into the embossing rollers to prepare the embossed graphite-based fiber web having a bipolar plate structure. Example

[0052] Example 1: Assembly of a system without heating This embodiment Figure 1 and Figure 2A set of seven calendering rolls 100 and two process rolls 200 can be assembled. The rolls can be configured as two calendering rolls in the melting zone 400, four calendering rolls in the kneading zone 500, and one calendering roll in the cooling / tempering zone 600.

[0053] A pair of process rollers 200 may be arranged directly adjacent to the last seventh calendering roller without a heating unit 300 (not shown) therebetween. The process rollers 200 may include one or more embossing rollers and / or one or more cutting rollers.

[0054] Example 2: Assembly of a system with heating This embodiment Figure 3 A set of seven calendering rolls 100 may be assembled. The calendering rolls may be configured as two calendering rolls in the melting zone 400, four calendering rolls in the kneading zone 500, and one calendering roll in the cooling / tempering zone 600.

[0055] A pair of process rollers 200 may be provided separately from the last seventh calendering roller. A heating unit 300 may be positioned before the process rollers 200. The process rollers 200 may include one or more embossing rollers and / or one or more cutting rollers.

[0056] Example 3: Use of a system without a heating unit This example describes the use of the system of Example 1. The set of calendaring rolls can be used to produce an untreated graphite-based fiber web. The fiber web is transferred directly from the calendaring rolls to a pair of processing rolls to produce a treated graphite-based fiber web having at least one bipolar plate structure. The treated fiber web is cooled and further processed as needed.

[0057] Example 4: Use of a system with a heating unit This example describes the use of the system of Example 2. The set of calendaring rollers can be used to produce an untreated graphite-based fiber web. The fiber web will be wound, cooled, and moved to a separate set of processing rollers.

[0058] The untreated web is heated using a heating unit to reach the desired processing temperature and then passed to processing rollers to produce a treated graphite-based web having at least one bipolar plate structure. The treated web is then cooled and further processed as needed.

[0059] Example 5: Comparison of systems with and without heating The system of Example 1 is expected to operate with improved efficiency, consistency, and energy usage relative to the system of Example 2. Specifically, the omission of the heating unit between the calender roll and the process roll is expected to significantly reduce energy usage and capital expenditure (capex) / operating expenditure (opex). Additionally, the simpler system is expected to have less unplanned downtime due to a lower frequency of failures and unplanned maintenance requirements.

[0060] Example 6: Comparison of Treated Products Produced The finished treated graphite-based fiber webs having at least one bipolar plate structure produced by Examples 3 and 4 can be compared. It is expected that the treated fiber webs produced by the direct system lacking a heating unit (as described in Examples 1 and 3) will be superior in quality to those produced by the indirect system having a heating unit (as described in Examples 2 and 4).

[0061] Example 7: Preparation of treated fiber webs from graphite flakes or powder Will use Figure 1 The graphite powder or flakes are loaded between the first two calendering rollers, where they are melted in the melting zone. The graphite powder or flakes then pass into the kneading zone and then into the cooling / tempering zone, resulting in an untreated fiber web. The untreated fiber web is then passed directly to the processing rollers to form a processed graphite-based fiber web with a bipolar plate structure. The fiber web does not leave contact with the roller or rollers until it has been processed.

[0062] In the above detailed description, reference is made to the accompanying drawings, which form a part thereof. In the drawings, like reference numerals generally identify like parts, unless the context indicates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It should be readily understood that the various aspects of the present disclosure, as generally described herein and shown in the drawings, may be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are expressly contemplated herein.

[0063] The present disclosure is not limited in terms of the specific embodiments described in this application, which are intended to be illustrative of various aspects. It will be clear to those skilled in the art that many modifications and variations can be made without departing from its spirit and scope. In addition to the methods and apparatus listed herein, it will be clear to those skilled in the art from the above description that there are also functionally equivalent methods and apparatus within the scope of the present disclosure. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is limited only by the terms of the appended claims and the full scope of equivalents to which such claims are entitled. It should be understood that the present disclosure is not limited to specific methods, materials, compositions or systems, which may, of course, vary. It should also be understood that the terms used herein are for the purpose of describing specific embodiments only and are not intended to be restrictive.

[0064] As used in this document, the singular forms "a," "an," and "the" include plural referents unless the context clearly indicates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Nothing in this disclosure should be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term "including" means "including, but not limited to."

[0065] Although various compositions, methods, and apparatus are described as "comprising" various components or steps (interpreted to mean "including but not limited to"), the compositions, methods, and apparatus may also "consist essentially of" or "consist of" the various components and steps, and such terms should be interpreted as limiting a substantially closed group of members.

[0066] With respect to substantially any plural and / or singular terms used herein, those skilled in the art can convert the plural to the singular and / or the singular to the plural, depending on the context and / or application. For clarity, various singular / plural arrangements may be explicitly listed herein.

[0067] Those skilled in the art will understand that, in general, the terms used herein, and especially in the appended claims (e.g., the bodies of the appended claims), are generally intended to be "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "including but not limited to," etc.). Those skilled in the art will also understand that if a specific number of recitations is intended for an introduced claim, such intent will be expressly recited in the claim, and if no such recitation is made, such intent is not present. For example, to aid understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that the introduction of a claim recitation by the indefinite article "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even if the same claim includes the introductory phrases "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be construed to mean "at least one" or "one or more"); the same applies to the use of definite articles to introduce claim recitations. In addition, even if a specific number of introduced claim recitations is explicitly stated, those skilled in the art will recognize that such recitation should be construed to mean at least the stated number (e.g., the mere recitation "two recitations" without other modifiers means at least two recitations or two or more recitations). Furthermore, in those instances where a convention similar to “at least one of A, B, and C, etc.” is used, such construction is generally intended in a sense that one skilled in the art would understand the convention to be (e.g., “a system having at least one of A, B, and C” would include, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and / or both A, B, and C, etc.). In those instances where a convention similar to “at least one of A, B, or C, etc.” is used, such construction is generally intended in a sense that one skilled in the art would understand the convention to be (e.g., “a system having at least one of A, B, or C” would include, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and / or both A, B, and C, etc.). One skilled in the art would also understand that, in practice, any transitional conjunctions and / or phrases indicating two or more alternative terms, whether in the specification, claims, or drawings, would be understood to contemplate the possibility of including one, either, or both of the terms. For example, the phrase "A or B" should be understood to include the possibilities of "A" or "B" or "A and B."

[0068] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0069] It will be understood by those skilled in the art that, for any and all purposes, such as with respect to providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be readily understood to fully describe and enable the same range to be decomposed into at least equal halves, thirds, quarters, fifths, tenths, etc. As non-limiting examples, each range discussed herein can be readily decomposed into a lower third, a middle third, and an upper third, etc. It will also be understood by those skilled in the art that all language, such as "up to," "at least," etc., includes the stated number and refers to a range that can subsequently be decomposed into the subranges discussed above. Finally, as will be understood by those skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 units refers to a group having 1, 2, or 3 units. Similarly, a group having 1-5 units refers to a group having 1, 2, 3, 4, or 5 units, etc.

[0070] The various features and functions disclosed above, as well as other features and functions, or alternatives thereto, may be combined into many other different systems or applications. Various currently unforeseen or unanticipated substitutions, modifications, variations, or improvements thereto may subsequently be made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.

Claims

1. A multi-roll process for producing a treated web having a bipolar plate structure, the process comprising: Providing a multi-roll calendering system, the multi-roll calendering system comprising one or more calendering rolls and one or more treatment rolls, wherein the system does not include any heating unit disposed between the calendering rolls and the embossing rolls; outputting an untreated web from the calendering roll; as well as feeding the untreated web to the treatment roll to produce the treated web having a bipolar plate structure; The one or more processing rollers include one or more cutting rollers, one or more embossing rollers and / or one or more combination rollers.

2. The method of claim 1, wherein the temperature of the untreated web upon output from the calendering roll is substantially the same as the temperature of the untreated web upon input to the treating roll.

3. The method according to claim 1, further comprising: The untreated web is cooled after it is output from the calendering rolls and before it is input to the treatment rolls.

4. The method of claim 1, wherein the untreated web is an untreated graphite-based web.

5. The method of claim 1, wherein the treated web is a treated graphite-based web.

6. The method of claim 1 , wherein the processing roll comprises at least one embossing roll or combination roll having convex embossing features and at least one embossing roll or combination roll having concave embossing features, the method further comprising: The male embossed features and the female embossed features are aligned.

7. The method of claim 1 , wherein the processing rollers include at least one cutting roller or combination roller having convex cutting features and at least one cutting roller or combination roller having concave cutting features, the method further comprising: The male cutting feature and the female cutting feature are aligned.

8. The method of claim 1, wherein the processing roll is positioned adjacent to the calendering roll.

9. A multi-roll system for producing a processed web having a bipolar plate structure, the system comprising: One or more calendering rolls and one or more process rolls; wherein: The system does not include any heating unit arranged between the calendering roll and the process roll, and The one or more processing rollers include one or more cutting rollers, one or more embossing rollers and / or one or more combination rollers.

10. The system of claim 9, configured such that the output of the calendering roll becomes the input of the processing roll.

11. The system of claim 9, configured such that the output of the calendering roll is an unprocessed web.

12. The system of claim 9, configured such that the output of the calendering roll is an unprocessed graphite-based web.

13. The system of claim 9, configured such that the output of the processing roller is a processed web having a bipolar plate structure.

14. The system of claim 9, configured such that the output of the processing roller is a processed graphite-based web having a bipolar plate structure.

15. The system of claim 9, comprising two or more calendaring rolls.

16. The system of claim 9 comprising seven calendaring rolls.

17. The system of claim 9 comprising 2, 3, 4, 5, 6, 7 or 8 calendaring rolls.

18. The system of claim 9 comprising two or more process rollers.

19. The system of claim 9 comprising 2 processing rollers.

20. The system of claim 9, comprising 2, 3, 4, 5, 6, 7 or 8 process rollers.

21. The system of claim 9, wherein the treated web having a bipolar plate structure is a treated graphite-based web having a bipolar plate structure.

22. A treated graphite-based web having a bipolar plate structure prepared by a multi-roll process, the method comprising: Providing a system comprising one or more calendering rolls and one or more process rolls; wherein the system does not include any heating unit disposed between the calendering roll and the processing roll; outputting an untreated graphite-based web from the calendering roll; and feeding the untreated graphite-based web to the processing roller to produce the treated graphite-based web having a bipolar plate structure; The one or more processing rollers include one or more cutting rollers, one or more embossing rollers and / or one or more combination rollers.

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