Systems and methods for the preconditioning of graphite plates

Abstract

Systems and methods are present for the preconditioning of graphite plates to achieve a graphite bipolar plate with minimal defects. An example of such a system comprises a platform to hold a graphite plate, a scoring tool to score the graphite plate, and a guide system to move the scoring tool along the length of the graphite plate.

Description

SYSTEMS AND METHODS FOR THE PRECONDITIONING OF GRAPHITE PLATESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority to and benefit of U.S. Provisional Application No. 63 / 533,509 filed August 18, 2023, the disclosure of which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] Fuel cells are electrochemical devices that can do work when electrochemically combining oxygen and hydrogen to generate electricity. The generated electricity can be used in any application that requires power to do work and can include but is not limited to: light, medium, and heavy duty motive power; fork lift operation; back-up generators; and stationary power as examples. A key fuel cell component is the bi-polar plate that has the following functions: direct fluids down channels; allow the diffusion of gases in channels to the fuel cell electrodes; facilitate current flowing from the anode to cathode side of the cell; direct coolant along a multitude of channels; allow for heat transfer from exothermic cathode reaction to the coolant stream to ensure desired thermal gradient is achieved; and to ensure there is effectively no leak pathway for one gas to leak to another gas or for any of the gas to leak to the coolant.

[0003] Currently, there are three main methods of forming fuel cell plates. One method is stamping metal plates. This results in bipolar plates that have good mechanical strength, but have limitations in forming some geometries, especially those not corrugated. A second method is compression molding resin bonded carbon or graphite. This can form most geometries but is a brittle material that is not suited for high production rates. The third method is resin impregnating flexible graphite. This method allows for high processing rates while allowing corrugated and non-corrugated features to be introduced without having a brittle part.

[0004] Current embossing of expandable graphite can achieve acceptable parts if landing tops are wide and the channel depths are low. However, if landing widths are reduced below 600 microns or channel depths are over 200 microns, the landing tops will not properly form unless the graphite is compressed to a high density where local areas can be compressed past the compressive strength of the graphite. This leads to fractures in the graphite. Therefore, in any flexible graphite made plate there is a balance between achieving a required density inthe graphite to form good flow channel landings and not over compressing the graphite causing stress fractures and failure. This balance is further exacerbated by the need to have the same plate thickness across the whole area of the plate while have having different channel geometries in different areas of the plate.

[0005] Expandable graphite is made from graphite flakes that are intercalated and then exfoliated to form a low-density material that is then calendared down to a specified thickness. The calendared graphite is then placed into die set which is compressed to specified thickness where the net shape of the part is produced. The net shape is constituted by channels formed in the graphite. These channels can be characterized by the depth of channel, the draft angle of channel, the top width of the channel, and the land width which represents the material between the top of the channel openings. These channels can be on only one side of the bipolar plate or can be on both sides of the bipolar plate. The channels can have the same pitch or a varied pitch. The channel geometry is typically varied in the different parts of the plates, including the center area where the majority of the fuel cell power is generated, the transition area where the gas or coolant is transported from a header area to the center area, and the perimeter sealing area.

[0006] The starting material for flexible graphite has a specified area weight that is selected to ensure a sufficient density is developed to form acceptable channel features, while not creating too high of a density in the thinnest webs of the plate. In recent years the fuel cell industry has started requiring fuel plate channel geometries that go outside conventional flexible graphite embossing limits. This has caused either poorly formed lands between the channels or the material to be densified to a level where some graphite at the bottom of the channel are pulled out causing unacceptable flow disturbances. In the extreme cases, the graphite is compressed to point of causing a stress fracture allowing a large leak through the plate. There exists a need for improved handling of graphite material in the creation of graphite plates to achieve plates with a smaller thickness, smaller landing widths, and larger channel depths without creating defects in the graphite.SUMMARY

[0007] In one embodiment, a processed graphite plate is produced by providing a graphite plate and a scoring tool; and preconditioning the graphite plate to create a processed graphite plate; wherein preconditioning the graphite plate includes forming at least one scored channel in the graphite plate by contacting the graphite plate with the scoring tool thereby causing graphite contained in the graphite plate to be deformed.

[0008] In some embodiments, preconditioning the graphite plate further includes embossing the graphite plate with an embossing tool to thereby impart the graphite plate with a plurality of embossed channels.

[0009] In some embodiments, each scored channel has a width that is greater than or equal to about 5% of the width of a corresponding embossed channel.

[0010] In some embodiments, each scored channel has a depth that is greater than or equal to about 5% of the depth of a corresponding embossed channel.

[0011] In some embodiments, the graphite plate includes the plurality of embossed channels which are formed in approximately the same location as the at least one scored channel.

[0012] In some embodiments, the processed graphite plate further includes a plurality of landings between each of the plurality of embossed channels.

[0013] In some embodiments, each of the plurality of landings has a width of about 0.2 mm to about 0.6 mm.

[0014] In some embodiments, each of the plurality of landings has a width of about 0.2 mm to about 0.3 mm.

[0015] In some embodiments, the ratio of the width of each of the plurality of landings to the depth of each of the plurality of embossed channels is about 1 :2 to about 2:1.

[0016] In some embodiments, the processed graphite plate has a thickness of about 0.3 mm to about 7 mm.

[0017] In some embodiments, each of the at least one scored channels has a depth of about 0.3 mm to about 3 mm.

[0018] In some embodiments, each of the at least one scored channels has a depth of about 0.4 mm to about 1 mm.

[0019] In some embodiments, each of the at least one scored channels has a depth of about 0.5 mm to about 0.7 mm.

[0020] In some embodiments, the at least one scored channel is formed by one of blade cutting, laser ablation, routering, milling, or scooping.

[0021] In some embodiments, each of the at least one scored channels are in parallel.

[0022] In some embodiments, the scoring tool is a knife.

[0023] In some embodiments, the knife includes multiple blades and each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.

[0024] In one embodiment, a system for processing a graphite plate includes a platform configured to hold the graphite plate; a scoring tool configured to create at least one scoredchannel in the graphite plate; and a guide system attached to the scoring tool and configured to move along the length of the graphite plate.

[0025] In some embodiments, the scoring tool is a ganged knife including multiple blades configured to rake the graphite plate.

[0026] In some embodiments, each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.

[0027] In some embodiments, the scoring tool is made from a single blade including multiple teeth configured to rake the graphite plate.

[0028] In some embodiments, the platform includes multiple pores, and the system further includes a vacuum pump configured to create a vacuum under the platform and to hold the graphite plate in position on the platform.

[0029] In some embodiments, the guide system is attached to the platform by a mechanical arm, wherein the mechanical arm is configured to hold the scoring tool and move to the guide system between a position adjacent to the platform and a position away from the platform.

[0030] In some embodiments, the scoring tool is a laser.

[0031] In some embodiments, the platform is configured to move the graphite plate across the scoring tool.

[0032] In one embodiment, a method of processing a graphite plate includes providing a graphite plate; providing a scoring tool; and forming at least one scored channel in the graphite plate by contacting the graphite plate with the scoring tool thereby causing graphite contained in the graphite plate to be deformed.

[0033] In some embodiments, the scoring tool is a ganged knife including multiple blades configured to rake the graphite plate.

[0034] In some embodiments, the scoring tool is attached to a guide system; and, forming the at least one scored channel includes moving the scoring tool along the length of the graphite plate.

[0035] In some embodiments, forming the at least one scored channel includes moving the scoring tool along the length of the graphite plate one time.

[0036] In some embodiments, forming the at least one scored channel includes moving the scoring tool along the length of the graphite plate between 2 and 10 times.

[0037] In some embodiments, the scoring tool is attached to a guide system; and, forming the at least one scored channel includes moving the graphite plate along the scoring tool.

[0038] In some embodiments, forming the at least one scored channel in the graphite plate using the scoring tool includes: contacting the graphite plate with the scoring tool; moving the scoring tool along the length of the graphite plate.

[0039] In some embodiments, the method further includes providing an embossing tool; and embossing the graphite plate to form a processed graphite plate with embossed channels.

[0040] In some embodiments, the processed graphite plate has a thickness of about 0.3 mm to about 0.35 mm.

[0041] In some embodiments, each of the at least one scored channels has a width that is greater than or equal to about 5% of the width of the embossed channels.

[0042] In some embodiments, each scored channel has a depth that is greater than or equal to about 5% of the depth of a corresponding embossed channel.

[0043] In some embodiments, the embossed channels are formed in approximately the same location as the at least one scored channel.

[0044] In some embodiments, the processed graphite plate further includes a plurality of landings between each of the embossed channels.

[0045] In some embodiments, each of the plurality of landings has a width of about 0.2 mm to about 0.6 mm.

[0046] In some embodiments, each of the plurality of landings has a width of about 0.2 mm to about 0.3 mm.

[0047] In some embodiments, the ratio of the width of each of the plurality of landings to the depth of each of the embossed channels is about 1:2 to about 2: 1.

[0048] In some embodiments, the processed graphite plate has a thickness of about 0.3 mm to about 7 mm.

[0049] In some embodiments, each of the at least one scored channels has a depth of about 0.4 mm to about 3 mm.

[0050] In some embodiments, each of the at least one scored channels has a depth of about 0.4 mm to about 1 mm.

[0051] In some embodiments, each of the at least one scored channels has a depth of about 0.5 mm to about 0.7 mm.

[0052] In some embodiments, forming the at least one scored channel is performed by one of laser ablation, routering, milling, or scooping.

[0053] In some embodiments, each of the at least one scored channels are in parallel.

[0054] In some embodiments, the scoring tool is a knife.

[0055] In some embodiments, the knife includes multiple blades and each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.BRIEF DESCRIPTION OF THE DRAWINGS

[0056] FIG. 1 depicts an illustrative system for preconditioning graphite having a scoring tool in accordance with an embodiment.

[0057] FIG. 2 depicts an illustrative system for preconditioning graphite having a scoring tool in accordance with an embodiment.

[0058] FIG. 3 depicts an illustrative scoring tool for preconditioning graphite in accordance with an embodiment.

[0059] FIG. 4A depicts an illustrative scoring tool for preconditioning graphite in accordance with an embodiment.

[0060] FIG. 4B depicts an illustrative scoring tool for preconditioning graphite in accordance with an embodiment.

[0061] FIG. 4C depicts an illustrative scoring tool for preconditioning graphite in accordance with an embodiment.

[0062] FIG. 5 A depicts an illustrative embossing tool for processing graphite in accordance with an embodiment.

[0063] FIG. 5B depicts an illustrative embossing tool for processing graphite in accordance with an embodiment.

[0064] FIG. 6 depicts a diagram for a method of preconditioning graphite in accordance with an embodiment.

[0065] FIG. 6 depicts an illustrative graphite plate in accordance with an embodiment.

[0066] FIG. 7 depicts an illustrative processed graphite plate in accordance with an embodiment.DEFINITIONS

[0067] As used herein, the term “about” when immediately preceding a numerical value means a range of plus or minus 10% of that value, for example, “about 50” means 45 to 55, “about 25,000” means 22,500 to 27,500, etc., unless the context of the disclosure indicates otherwise, or is inconsistent with such an interpretation.

[0068] As used herein, the term ‘'pitch” is used to describe the distance from the center of a channel of a graphite plate to the center of an adjacent channel of the graphite plate. For example, the pitch of a graphite plate may be about 1.0 mm.

[0069] As used herein, the term “area weight” is used to describe the amount of graphite in specified area. For example, an area weight of 50 milligrams per centimeter, or 50 mg / cm2, indicates that there are 50 milligrams of graphite in a 1 cm by 1 cm area. The density of the material can be calculated by multiplying the area weight of the graphite by the thickness of the sample.

[0070] As used herein, the term “ganged knife” is used to describe a knife comprising multiple adjacent blades. For example, a ganged knife may be a knife comprising 100 adjacent blades wherein the blades have the same orientation.

[0071] The present disclosure is not to be limited in terms of the particular embodiments described in this application, which are intended as illustrations of various aspects. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and apparatuses within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the descriptions. Such modifications and variations are intended to fell within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds, compositions or biological systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

[0072] As used in this document, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to 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 “comprising” means “including, but not limited to.”

[0073] While various compositions, methods, and devices are described in terms of "comprising" various components or steps (interpreted as meaning "including, but not limited to"), the compositions, methods, and devices can also "consist essentially of or "consist of the various components and steps, and such terminology should be interpreted as defining essentially closed-member groups.

[0074] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0075] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (for example, bodies of the appended claims) are generally intended as “open” terms (for example, 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 “includes but is not limited to,” etc.). It will be further understood by those skilled in the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to 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 to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (for example, “a” and / or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “ a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “ a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and Ctogether, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0076] 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.

[0077] As will be understood by one skilled in the art, for any and all purposes, such as in terms of 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 easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member. Thus, for example, a group having 1-3 cells refers to groups having 1, 2, or 3 cells. Similarly, a group having 1-5 cells refers to groups having 1, 2, 3, 4, or 5 cells, and so forth.DETAILED DESCRIPTION

[0078] This 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 the particular versions or embodiments only and is not intended to limit the scope.

[0079] Systems

[0080] Systems can be assembled to aid in the preconditioning of graphite plates prior to the embossing of the graphite plates. In some embodiments, the system comprises a platform, a scoring tool, and a guide system. In some embodiments, the system further comprises a mechanical arm configured to move the system between an open position and a closed position. The system is configured to precondition a graphite plate to reduce the number of defects and improve the quality of the graphite plate after embossing in comparison to anembossed graphite plate that was not preconditioned. The preconditioning may further enable improved landing formation of the graphite plate after embossing in comparison to an embossed graphite plate that was not preconditioned. The preconditioning of the graphite plate can prepare the graphite plate for embossing and produce an embossed graphite plate with a thickness of about 0.30 mm, about 0.35 mm, about 0.40 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm, about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1 .4 mm, about 1.5 mm, about 1 .6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, about 5.0 mm, about 5.5 mm, about 6.0 mm, about 6.5 mm, or about 7.0 mm. The preconditioning of the graphite plate can prepare the graphite plate for embossing and produce an embossed graphite plate with a thickness of about 0.3 mm to about 7.0 mm, about 0.4 mm to about 1.0 mm, or about 0.45 mm to about 0.55 mm.

[0081] FIG. 1 illustrates a system with a scoring tool 101 configured to create at least one scored channel in a graphite plate, a guide system 102 configured to move along the length of a platform 103 configured to hold the graphite plate. In some embodiments, the scoring tool 101 is attached to the guide system 102 and is configured to move with the guide system 102 along the length of the platform 103. In some embodiments, the system further comprises a mechanical arm 104 configured to move the system from a closed position in which the scoring tool 101 is adjacent to the platform 103 and an open position in which is scoring tool 101 is positioned away fiom the platform 103. FIG. 1 depicts the system in the open position.

[0082] The scoring tool 101 can be any tool effective for the scoring of graphite known to one of ordinary skill in the art. In some embodiments, the scoring tool 101 is an oscillating knife, a drag knife, a CNC knife, a CNC router, a ganged knife, a rolling knife, a blade scoring knife, a laser or a flash cut knife. The scoring tool 101 can comprise and material effective for the scoring of graphite known to one of ordinary skill in the art. In some embodiments, the scoring tool 101 comprises low carbon steel or tool steel. In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate without affecting the material between the channels of the graphite plate. In some embodiments, multiple scoring tools can be used in the system. The multiple scoring tools can be the same type of tool or different types of tools.

[0083] The scoring tool 101 is configured to create at least one scored channel in the graphite plate. In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the depth of each of the at least one scored channels is less than about 90% of the thickness of the graphite plate. In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the depth of each of the at least one scored channels is greater than or equal to about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the thickness of the desired channel thickness of the graphite plate after the graphite plate is embossed.

[0084] In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the depth of the at least one scored channel is about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 3.0 mm, or any value between any two of these values. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the depth of each of the at least one scored channels is about 0.1 mm to about 1.0 mm, about 0.2 mm to about 0.5 mm, about 0.3 mm to about 3.0 mm, or about 0.35 mm to about 0.38 mm.

[0085] In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the pitch of the graphite plate is equal to the pitch of channel forming features present on an embossing die used to emboss the graphite plate. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch of the at least one scored channel is about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, or any value between any two of these values. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch of each of the at least one scored channels is about 0.5 mm to about 2.0 mm, about 0.58 mm to about 1.0 mm, or about 0.8 mm to about 1.2 mm.

[0086] In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch of the at least one scored channel is about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired pitch of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch of the at least one scored channel is greater than about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired pitch of the graphite plate after the graphite plate is embossed.

[0087] In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the width of each of the at least one scored channels is configured to be equal to the desired channel width of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the width of each of the at least one scored channels is configured to be about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel width of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool 101 is configured to create at least one scored channel in the graphite plate, wherein the width of each of the at least one scored channels is configured to be greater than about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel width of the graphite plate after the graphite plate is embossed.

[0088] In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the width of each of the at least one scored channels is about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, or any value between any two of these values. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the width of each of the at least one scored channels is about 0.1 mm to about 1.0 mm, about 0.2 mm to about 0.8 mm, or about 0.35 mm to about 0.45 mm.

[0089] The guide system 102 is configured to consistently move along the length of the platform 103 in a straight line. In some embodiments, the guide system 102 comprises two guide rails 105 positioned parallel to the length of the platform, and a guide structure positioned between the two guide rails 105 configured to attach the scoring tool 101 to theguide system 102. In some embodiments, the scoring tool 101 is configured to be replaced from the guide system 102 The scoring tool 101 can be attached to the guide system 102 by any means known to one of ordinary skill in the art effective for securing a scoring tool to a guide structure. In some embodiments, the scoring tool 101 is attached to the guide system 102 by one or more bolts, fasteners, staples, nails, screws, rivets, glue, clamps, or any combination of the above. In some embodiments, the height of the guide system 102 is adjustable to allow for a change in the depth of the scoring of the graphite plate.

[0090] In some embodiments, the platform 103 is configured to maintain the position of the graphite plate during the preconditioning of the graphite plate. The platform 103 can maintain the position of the graphite plate by any means known to one of ordinary skill in the art effective for securing a graphite plate. In some embodiment, the platform 103 further comprises fasteners or clamps configured to maintain the position of the graphite plate. In some embodiments, the platform 103 comprises multiple pores, and the system further comprises a vacuum pump configured to create a vacuum under the platform and to hold the graphite plate in position on the platform 103.

[0091] In some embodiments, the platform 103 is configured to move the graphite plate across the scoring tool 101. The platform 103 can move the graphite plate across the scoring tool 101 by any method known to one of ordinary skill in the art. In some embodiments, the platform is attached to a platform guiding system configured to move the platform 103 across the scoring tool 101 in a straight line. In some embodiments, the platform 103 is a calender roller or a conveyor belt.

[0092] FIG. 2 illustrates a system with a scoring tool 201 configured to create at least one scored channel in a graphite plate, a guide system 202 configured to move along the length of a platform 203 configured to hold the graphite plate. In some embodiments, the scoring tool 201 is attached to the guide system 202 and is configured to move with the guide system 202 along the length of the platform 203. In some embodiments, the system further comprises a mechanical arm 204 configured to move the system from a closed position in which the scoring tool 201 is adjacent to the platform 203 and an open position in which is scoring tool 201 is positioned away from the platform 203. FIG. 2 depicts the system in the closed position.

[0093] In some embodiments, the system further comprises at least one handle 205 configured to allow a user to move the guide system 202 along the length of the platform 203. In some embodiments, the system further comprises a drivetrain, wherein the drivetrain is attached to the guide system 202 and is configured to move the guide system 202 along thelength of the platform 203. In some embodiments, the drivetrain is configured to move the guide system 202 along the length of the platform 203 using the handle 205.

[0094] FIG. 3 illustrates a ganged knife comprising multiple blades 301 configured to rake a graphite plate. In some embodiments, the ganged knife further comprises multiple holes 302 configured to allow the ganged knife to be attached to a guide system. The ganged knife can have any number of blades 301. In some embodiments, the ganged knife has 50 blades, 60 blades, 70 blades, 80 blades, 90 blades, 100 blades, 110 blades, 120 blades, 130 blades, 140 blades, 150 blades, 160 blades, 170 blades, 180 blades, 190 blades, 200 blades, or any number between any two of these numbers. In some embodiments, the ganged knife has 100 to 200 blades.

[0095] FIG. 4A illustrates a portion of a ganged knife comprising multiple blades 401 configured to rake a graphite plate. In some embodiments, each of the multiple blades 401 comprises an angled tip, wherein the angled tip comprises an edge angle θ and a blade angle φ. In some embodiments, the edge angle θ is measured as the angle from the tip of the blades 401 to the base of the blades 401. The edge angle θ is indicated in FIG. 4A as the angle between the first side 403 of the blade 401 and the second side 405 of the blade 401. In some embodiments, each of the angled tips has an edge angle 6 of about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, or any value between any two of these values. In some embodiments, each of the angled tips has an equal edge angle θ. In some embodiments, each of the angled tips has a different edge angle θ. In some embodiments, each of the angled tips has an edge angle θ of about 30 degrees to about 70 degrees.

[0096] FIG. 4B illustrates a side view of a ganged knife. In some embodiments, the blade angle φ is measured as the angle from the back 407 of the blades 401 to the front 406 of the blades 401. The blade angle φ is indicated in FIG. 4B as the angle between the back 407 of the blade 401 and the front 406 of the blade 401. In some embodiments, each of the angled tips has a blade angle <p of about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, or any value between any two of these values. In some embodiments, each of the angled tips has an equal blade angle φ. In some embodiments, each of the angled tips has a different blade angle φ. In some embodiments, each of the angled tips has a blade angle <p of about 30 degrees to about 70 degrees.

[0097] FIG. 4C illustrates a side view of a scoring tool 408 configured to form at least one scored channel in a graphite plate 409. The scoring angle α is measured as the angle from the front of the scoring tool 408 to the surface of the graphite plate 409. In some embodiments, the scoring angle α is about 15 degrees, about 20 degrees, about 25 degrees, about 30 degrees, about 35 degrees, about 40 degrees, about 45 degrees, about 50 degrees, about 55 degrees, about 60 degrees, about 65 degrees, about 70 degrees, about 75 degrees, about 80 degrees, about 85 degrees, about 90 degrees, about 95 degrees, about 100 degrees, about 105 degrees, about 110 degrees, about 115 degrees, about 120 degrees, or any value between any two of these values.

[0098] In some embodiments, the pitch 402 of the multiple blades 401 is about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, about 4.0 mm, about 4.1 mm, about 4.2 mm, about 4.3 mm, about 4.4 mm, about 4.5 mm, about 4.6 mm, about 4.7 mm, about 4.8 mm, about 4.9 mm, about 5.0 mm, or any value between any two of these values. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch 402 of the multiple blades 401 is about 0.5 mm to about 2.0 mm, about 0.58 mm to about 1.0 mm, or about 0.8 mm to about 1.2 mm.

[0099] In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch 402 of the multiple blades 401 is about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired pitch of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool 101 is configured to create at least one scored channel, wherein the pitch 402 of the multiple blades 401 is greater than about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired pitch of the graphite plate after the graphite plate is embossed.

[0100] In some embodiments, the depth 404 of the multiple blades 401 is about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm,about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, or any value between any two of these values. In some embodiments, the depth 404 of the multiple blades 401 is about 0.1 mm to about 1.0 mm, about 0.2 mm to about 0.5 mm, or about 0.35 mm to about 0.38 mm.

[0101] FIG. 5A illustrates an embossing tool comprising atop embossing die 501 and a bottom embossing die 502 configured to emboss a graphite plate 503. The top embossing die 501 comprises a plurality of die channel forming features 504 which are configured to created embossed channels in the graphite plate 503. In some embodiments, each of the plurality of die channel forming features 504 is aligned in approximately the same location as the at least one scored channel 505. The top embossing die 501 further comprises a plurality of landing forming features 506 configured to form the landings of the embossed graphite plate. In some embodiments, each of the plurality of landing forming features 506 is positioned between each of the plurality of die channel forming features 504. FIG. 5B illustrates an embossing tool contacting a graphite plate 503 to emboss the graphite plate 503.

[0102] Methods of use

[0103] Methods can be performed to precondition a graphite plate using the above-described systems for the embossing of graphite bipolar plates.

[0104] FIG. 6 illustrates a diagram for preconditioning a graphite plate. The method comprises providing 601 a graphite plate, providing 602 a scoring tool, and forming 603 at least one scored channel in the graphite plate using the scoring tool. In some embodiments, forming 603 the at least one scored channel comprises contacting the graphite plate with the scoring tool and moving the scoring tool along the length of the graphite plate thereby causing graphite contained in the graphite plate to be deformed. In some embodiments, forming 603 the at least one scored channel comprises contacting the scoring tool with the graphite plate and moving the graphite plate along the scoring tool. The scoring tool can be any tool effective for the scoring of graphite known to one of ordinary skill in the art. In some embodiments, the scoring tool is an oscillating knife, a drag knife, a CNC knife, a CNC router, a ganged knife, a rolling knife, a blade scoring knife, a laser or a flash cut knife.

[0105] In some embodiments, the scoring tool is attached to a guide system and forming 603 the at least one scored channel comprises moving the scoring tool along the length of the graphite plate. Forming 603 the at least one scored channel can comprise moving the scoring tool along the length of the graphite plate any number of times. In some embodiments, forming 603 the at least one scored channel comprises moving the scoring tool along thelength of the graphite plate one time. In some embodiments, forming 603 the at least one scored channel comprises moving the scoring tool along the length of the graphite plate multiple times. In some embodiments, forming 603 the at least one scored channel comprises moving the scoring tool along the length of the graphite plate 1 time, 2 times, 3 times, 4 times, 5 times, 6 times, 7 times, 8 times, 9 times, or 10 times. In some embodiments, the scoring tool forms 603 scored channels on one side of the graphite plate. In some embodiments, the scoring tool forms 603 scored channels on both sides of the graphite plate. In some embodiments, each of the at least one scored channels are in parallel.

[0106] In some embodiments, forming 603 the at least one scored channel comprises a continuous scoring. In such an embodiment, the deformation on the graphite plate may comprise one or more lines comprising a predetermined depth, pitch, angle, and width.

[0107] In some embodiments, forming 603 the at least one scored channel comprises an intermittent scoring. In such as embodiment, the deformation on the graphite plate may comprise one or more points comprising a predetermined shape and size. In some embodiments, the predetermined shape may comprise a depth of at least about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel depth of the graphite plate after the graphite plate is embossed. In some embodiments, the predetermined shape may comprise a width of at least about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel depth of the graphite plate after the graphite plate is embossed.

[0108] In some embodiments, the scoring tool is a ganged knife comprising multiple blades configured to rake the graphite plate. In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the depth of each of the at least one scored channels is less than about 90% of the thickness of the graphite plate. In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the depth of each of the at least one scored channels is greater than or equal to about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the thickness of the desired channel thickness of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the depth of the each of the at least one scoredchannels is about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 3.0 mm, or any value between any two of these values. In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the depth of each of the at least one scored channel is about 0.1 nun to about 1.0 mm, about 0.2 mm to about 0.5 mm, about 0.3 mm to about 3.0 mm, or about 0.35 mm to about 0.38 mm.

[0109] In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the pitch of the graphite plate is equal to the pitch of channel forming features present on an embossing die used to emboss the graphite plate. In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the pitch of each of the at least one scored channel is about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1 .7 mm, about 1.8 mm, about 1 .9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.1 mm, about 3.2 mm, about 3.3 mm, about 3.4 mm, about 3.5 mm, about 3.6 mm, about 3.7 mm, about 3.8 mm, about 3.9 mm, about 4.0 mm, about 4.1 mm, about 4.2 mm, about 4.3 mm, about 4.4 mm, about 4.5 mm, about 4.6 mm, about 4.7 mm, about 4.8 mm, about 4.9 mm, about 5.0 mm, or any value between any two of these values. In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the pitch of each of the at least one scored channel is about 0.5 mm to about 2.0 mm, about 0.58 mm to about 1.0 mm, or about 0.8 mm to about 1.2 mm.

[0110] In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the width of each of the at least one scored channels is configured to be equal to the desired channel width of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the width of each of the at least one scored channels is configured to be about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel width of the graphite plate after the graphite plate is embossed. In some embodiments, the scoring tool forms 603 at least one scored channel in the graphite plate, wherein the width of each of the at least one scoredchannels is configured to be greater than about 5%, about 10%, about 15%, about 20%, about 25%, 30%, about 35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%, about 90%, or about 95% of the desired channel width of the graphite plate after the graphite plate is embossed.

[0111] In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the width of each of the at least one scored channels is about 0.1 nun, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, or any value between any two of these values. In some embodiments, the scoring tool forms 603 at least one scored channel, wherein the width of each of the at least one scored channels is about 0.1 mm to about 1.0 mm, about 0.2 mm to about 0.8 nun, or about 0.35 mm to about 0.45 mm.

[0112] In some embodiments, the method further comprises affixing the graphite plate to a platform prior to forming 603 the at least one scored channel in the graphite plate. In some embodiments, the graphite plate is affixed to the platform by one of fasteners or clamps configured to maintain the position of the graphite plate. In some embodiments, the platform comprises multiple pores, and the graphite plate is affixed to the platform by a vacuum under the platform configured to hold the graphite plate in position on the platform. In some embodiments, the method further comprises removing the graphite plate from the platform after forming 603 the at least one scored channel in the graphite plate. In some embodiments, the method further comprises cleaning the scoring tool after removing the graphite plate from the platform. In some embodiments, cleaning the scoring tool comprises removing graphite from the scoring tool.

[0113] In some embodiments, the method further comprises providing an embossing tool and embossing the graphite plate to form a processed graphite plate with embossed channels. In some embodiments, the embossing tool is an embossing roller. In some embodiments, the embossed channels are formed in approximately the same location as the at least one scored channel. In some embodiments, the embossed graphite plate has a thickness of about 0.30 mm, about 0.35 mm, about 0.40 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm, about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 nun, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 nun, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.5 mm, about 4.0 nun, about 4.5 mm, about 5.0 nun, about 5.5 nun, about 6.0 mm, about 6.5 nun,about 7.0 mm, or any value between any two of these values. In some embodiments, the embossed graphite plate has a thickness of about 0.3 mm to about 7.0 mm, about 0.4 mm to about 1.0 mm, or about 0.30 mm to about 0.35 mm.

[0114] In some embodiments, each of the at least one scored channels has a width that is about 5% of the width of the embossed channels, about 10% of the width of the embossed channels, about 15% of the width of the embossed channels, about 20% of the width of the embossed channels, about 25% of the width of the embossed channels, about 30% of the width of the embossed channels, about 35% of the width of the embossed channels, about 40% of the width of the embossed channels, about 45% of the width of the embossed channels, 50% of the width of the embossed channels, about 55% of the width of the embossed channels, 60% of the width of the embossed channels, about 65% of the width of the embossed channels, 70% of the width of the embossed channels, about 75% of the width of the embossed channels, or any value between any two of these values. In some embodiments, each of the at least one scored channels has a width that is about 40% to about 70% of the width of the embossed channels. In some embodiments, each of the at least one scored channels has a width that is at least about 5% of the width of the embossed channels, at least about 10% of the width of the embossed channels, at least about 15% of the width of the embossed channels, at least about 20% of the width of the embossed channels, at least about 25% of the width of the embossed channels, at least about 30% of the width of the embossed channels, at least about 35% of the width of the embossed channels, at least about 40% of the width of the embossed channels, at least about 45% of the width of the embossed channels, 50% of the width of the embossed channels, at least about 55% of the width of the embossed channels, 60% of the width of the embossed channels, at least about 65% of the width of the embossed channels, 70% of the width of the embossed channels, at least about 75% of the width of the embossed channels, or any value between any two of these values.

[0115] In some embodiments, the processed graphite plate further comprises a plurality of landings between each of the embossed channels. In some embodiments, each of the plurality of landings has a width of about 0.20 mm, about 0.21 mm, about 0.22 mm, about 0.23 mm, about 0.24 mm, about 0.25 mm, about 0.26 mm, about 0.27 mm, about 0.28 mm, about 0.29 mm, about 0.30 mm, about 0.31 mm, about 0.32 mm, about 0.33 mm, about 0.34 mm, about 0.35 mm, about 0.36 mm, about 0.37 mm, about 0.38 mm, about 0.39 mm, about 0.40 mm, about 0.41 mm, about 0.42 mm, about 0.43 mm, about 0.44 mm, about 0.45 mm, about 0.46 mm, about 0.47 mm, about 0.48 mm, about 0.49 mm, about 0.50 mm, about 0.51 mm, about 0.52 mm, about 0.53 mm, about 0.54 mm, about 0.55 mm, about 0.56 mm, about 0.57 mm,about 0.58 mm, about 0.59 mm, about 0.60 mm, or any value between any two of these values. In some embodiments, each of the plurality of landings has a width of about 0.2 mm to about 0.6 mm or about 0.20 mm to about 0.30 mm.

[0116] In some embodiments, each of the embossed channels has a depth of about 0.4 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1 .9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, or any value between any two of these values. In some embodiments, each of the embossed channels has a depth of about 0.4 mm to about 3 mm, 0.4 mm to about 1 mm, or about 0.5 mm to about 0.7 mm. In some embodiments, the ratio of the width of each of the plurality of landings to the depth of each of the embossed channels is about l:10 to about 10:1, about 1:5 to about 5:1, about 1:3 to about 3:1, or about 1:2 to about 2:1.

[0117] Graphite Plates

[0118] The graphite plate can have any number of embossed channels. In some embodiments the graphite plate comprises about 100 embossed channels, about 110 embossed channels, about 120 embossed channels, about 130 embossed channels, about 140 embossed channels, about 150 embossed channels, about 160 embossed channels, about 170 embossed channels, about embossed 180 embossed channels, about 190 embossed channels, about 200 embossed channels, about 210 embossed channels, about 220 embossed channels, about 230 embossed channels, about 240 embossed channels, about 250 embossed channels about 260 embossed channels, about 270 embossed channels, about 280 embossed channels, about 290 embossed channels, about 300 embossed channels, or any value between any two of these values. In some embodiments, the graphite plate comprises about 150 embossed channels to about 200 embossed channels.

[0119] The graphite plate can comprise any number of the embossed channels per centimeter width of the graphite plate. In some embodiments, the graphite plate comprises about 5 embossed channels / cm, about 6 embossed chaxmels / cm, about 7 embossed channels / cm, about 8 embossed channels / cm, about 9 embossed channels / cm, about 10 embossed channels / cm, about 11 embossed channels / cm, about 12 embossed channels / cm, about 13 embossed channels / cm, about 14 embossed channels / cm, about 15 embossed channels / cm, about 16 embossed channels / cm, about 17 embossed channels / cm, about 18 embossedchannels / cm, about 19 embossed channels / cm, about 20 embossed channels / cm, or any value between any two of these values. In some embodiments, the graphite plate comprises about 12 embossed channels / mm to about 15 embossed channels / mm.

[0120] In some embodiments, each of the embossed channels has a depth of about 0.4 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1 .9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, or any value between any two of these values. In some embodiments, each of the embossed channels has a depth of about 0.4 mm to about 3 mm, 0.4 mm to about 1 mm, or about 0.5 mm to about 0.7 mm.

[0121] In some embodiments, the graphite plate has a thickness of about 0.30 mm, about 0.35mm, about 0.40 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm, about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm or any value between any two of these values. In some embodiments, the graphite plate has a thickness of about 0.3 mm to about 3.0 mm, about 0.4 mm to about 1.0 mm, or about 0.45 mm to about 0.55 mm.

[0122] In some embodiments, each of the embossed channels has a pitch of about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, or any value between any two of these values. In some embodiments, each of the multiple channels has a pitch of about 0.5 mm to about 2.0 mm, about 0.58 mm to about 1.0 mm, or about 0.8 mm to about 1.2 mm.

[0123] The graphite plate can have any density. In some embodiments, the graphite plate has a density of about 1.00 g / cc, about 1.05 g / cc, about 1.10 g / cc, about 1.15 g / cc, about 1.20 g / cc, about 1.25 g / cc, about 1.30 g / cc, about 1.35 g / cc, about 1.40 g / cc, about 1.45 g / cc, about 1.50 g / cc, about 1.55 g / cc, about 1.60 g / cc, about 1.65 g / cc, about 1.70 g / cc, about 1.75 g / cc, about 1.80 g / cc, about 1.85 g / cc, about 1.90 g / cc, about 1.95 g / cc, about 2.00 g / cc, or any value between any two of these values. In some embodiments, the graphite plate has a densityof about 1.00 g / cc to about 2.00 g / cc, about 1.20 g / cc to about 1.80 g / cc, or about 1.60 g / cc to about 1.75 g / cc.

[0124] Graphite plates prepared by the above-described process

[0125] Graphite plates can be produced using the above-described methods.

[0126] In some embodiments, a processed graphite plate is produced by providing a graphite plate and preconditioning the graphite plate to create a processed graphite plate wherein, the preconditioning of the graphite plate comprises providing a scoring tool and forming at least one scored channel in the graphite plate using the scoring tool. In some embodiments, the at least one scored channel is formed by one of blade cutting, laser ablation, routering, milling, or scooping. In some embodiments, the production of the processed graphite plate further comprises providing an embossing tool and embossing the graphite plate to thereby impart the graphite plate with a plurality of embossed channels. In some embodiments, the embossing tool is an embossing roller. In some embodiments, the embossing tool has multiple channel forming features. In some embodiments, each of the channel forming features has the same pitch as the at least one embossed channels, and each of the multiple channel forming features is placed in line with one of the at least one scored channels during embossing.

[0127] The processed graphite plate can generally have any thickness. In some embodiments, the processed graphite plate has a thickness of about 0.30 mm, about 0.35mm, about 0.40 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm, about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, about 3.5 mm, about 4.0 mm, about 4.5 mm, about 5.0 mm, about 5.5 mm, about 6.0 mm, about 6.5 mm, or about 7.0 mm or any value between any two of these values. In some embodiments, the processed graphite plate has a thickness of about 0.3 mm to about 7.0 mm, about 0.4 mm to about 1.0 mm, or about 0.30 mm to about 0.35 mm.

[0128] FIG. 7 illustrates a diagram of a processed graphite plate produced using the above- described methods. The processed graphite plate comprises a plurality of embossed channels 701 and a plurality of landings 702.

[0129] In some embodiments, each of the plurality of landings 702 has a width of about 0.20 mm, about 0.21 mm, about 0.22 mm, about 0.23 mm, about 0.24 mm, about 0.25 mm, about0.26 mm, about 0.27 mm, about 0.28 mm, about 0.29 mm, about 0.30 mm, about 0.31 mm, about 0.32 mm, about 0.33 mm, about 0.34 mm, about 0.35 mm, about 0.36 mm, about 0.37 mm, about 0.38 mm, about 0.39 mm, about 0.40 mm, about 0.41 mm, about 0.42 mm, about 0.43 mm, about 0.44 mm, about 0.45 mm, about 0.46 mm, about 0.47 mm, about 0.48 mm, about 0.49 mm, about 0.50 mm, about 0.51 mm, about 0.52 mm, about 0.53 mm, about 0.54 mm, about 0.55 mm, about 0.56 mm, about 0.57 mm, about 0.58 mm, about 0.59 mm, about 0.60 mm, or any value between any two of these values. In some embodiments, each of the plurality of landings 702 has a width of about 0.2 mm to about 0.6 mm or about 0.20 mm to about 0.30 mm.

[0130] In some embodiments, each of the embossed channels 701 has a depth 703 of about 0.4 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1.3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm, about 2.1 mm, about 2.2 mm, about 2.3 mm, about 2.4 mm, about 2.5 mm, about 2.6 mm, about 2.7 mm, about 2.8 mm, about 2.9 mm, about 3.0 mm, or any value between any two of these values. In some embodiments, each of the embossed channels 701 has a depth 703 of about 0.4 mm to about 3 mm, 0.4 mm to about 1 mm, or about 0.5 mm to about 0.7 mm. In some embodiments, the ratio of the width of each of the plurality of landings 702 to the depth 703 of each of the embossed channels 701 is about 1:10 to about 10:1, about 1:5 to about 5:1, about 1:3 to about 3:1, or about 1:2 to about 2:1.

[0131] In some embodiments, each of the embossed channels 701 has atop width 704 of about 0.2 mm, 0.25 mm, about 0.3 mm, about 0.35 mm, about 0.4 mm, about 0.45 mm, about 0.50 mm, about 0.55 mm about 0.60 mm, about 0.65 mm, about 0.70 mm, about 0.75 mm, about 0.80 mm, about 0.85 mm, about 0.90 mm, about 0.95 mm, about 1.0 mm, about 1.1 mm, about 1.2 mm, about 1 .3 mm, about 1.4 mm, about 1.5 mm, about 1.6 mm, about 1.7 mm, about 1.8 mm, about 1.9 mm, about 2.0 mm.EXAMPLESExample 1: No pre-conditioningA graphite sheet that has an area weight of 45 mg / cm2 and initial thickness of 1.5 mm was embossed with an embossing die set comprising a top embossing die and a bottom embossing die. The top embossing die had landing forming features of 240 microns with channelforming features of 370 microns. The channel forming features were configured to form channels with top widths of 810 microns. The top embossing die had landing forming features and channel forming features repeated 20 times with equal spacing between the channel forming features and the landing forming features. The bottom embossing die was flat. The graphite plate was embossed using the embossing die set and produced a graphite plate with a thickness of about 650 microns. Inspection of the graphite embossed lands showed poor landing quality as a result of the graphite not forming properly at the landings. This result shows a graphite sheet which would be permeable to liquids and gases.Example 2: Pre-conditioning with single knifeA graphite sheet was processed using the same embossing die set as in Example 1. Prior to embossing the graphite, cut lines were put into the graphite surface with a standard cutting blade. The cut lines had a depth of about 600 microns and a top width of about 450 microns. The cut lines were formed with a single blade. 20 cut lines were formed with the same pitch as the top embossing die. The cut lines were put into the graphite at a pitch where the center of the cut line is about in the center of the channel forming features of the top embossing die. The graphite was embossed using the embossing die set and produced a graphite plate with a thickness of about 650 microns. Inspection of the graphite embossed lands show foil landings formed with no defects. This result shows that the use of the preconditioning results in folly formed graphite sheets which would have improved properties to the embossed sheet of Example 1 as the sheet would not be permeable to liquids and gases.Example 3: Pre-conditioning with simultaneous cuttingA graphite sheet was processed using the same embossing die set as in Example 1. Prior to embossing the graphite, cut lines were put into the graphite surface with a standard cutting blade. The cut lines had a depth of about 600 microns and a top width of about 450 microns. The cut lines were formed with a custom cutting blade which included 20 teeth configured to form cut lines in the graphite. 20 cut lines were formed with the same pitch as the top embossing die. The cut lines were put into the graphite at a pitch where the center of the cut tine is about in the center of the channel forming features of the top embossing die. The graphite was embossed using the embossing die set and produced a graphite plate with a thickness of about 650 microns. Inspection of the graphite embossed lands show foil landings formed with no defects. This result shows that the use of the preconditioning resultsin folly formed graphite sheets which would have improved properties to the embossed sheet of Example 1 as the sheet would not be permeable to liquids and gases.Example 4: Pre-conditioning with removing graphiteA graphite sheet was processed using the same embossing die set as in Example 1. Prior to embossing the graphite, cut lines were put into the graphite surface with a standard cutting blade. The cut lines had a depth of about 600 microns and a top width of about 450 microns. The cut lines were formed with a micro router bit configured to form cut lines in the graphite. 20 cut lines were formed with the same pitch as the top embossing die. The cut lines were put into the graphite at a pitch where the center of the cut line is about in the center of the channel forming features of the top embossing die. The graphite was embossed using the embossing die set and produced a graphite plate with a thickness of about 650 microns. Inspection of the graphite embossed lands show full landings formed with no defects. This result shows that the use of the preconditioning results in fully formed graphite sheets which would have improved properties to the embossed sheet of Example 1 as the sheet would not be permeable to liquids and gases.

[0132] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.

Claims

CLAIMS1. A processed graphite plate, wherein the processed graphite plate is produced by: providing a graphite plate and a scoring tool; and preconditioning the graphite plate to create a processed graphite plate; wherein preconditioning the graphite plate includes forming at least one scored channel in the graphite plate by contacting the graphite plate with the scoring tool thereby causing graphite contained in the graphite plate to be deformed.

2. The processed graphite plate of claim 1, wherein preconditioning the graphite plate further includes embossing the graphite plate with an embossing tool to thereby impart the graphite plate with a plurality of embossed channels.

3. The processed graphite plate of any one of claims 1 and 2, wherein each scored channel has a width that is greater than or equal to about 5% of the width of a corresponding embossed channel.

4. The processed graphite plate of any one of claims 1 and 2, wherein each scored channel has a depth that is greater than or equal to about 5% of the depth of a corresponding embossed channel.

5. The processed graphite plate of claim 2, wherein the graphite plate includes the plurality of embossed channels which are formed in approximately the same location as the at least one scored channel.

6. The processed graphite plate of claim 2, further comprising a plurality of landings between each of the plurality of embossed channels.

7. The processed graphite plate of claim 6, wherein each of the plurality of landings has a width of about 0.2 mm to about 0.6 mm.

8. The processed graphite plate of claim 6, wherein each of the plurality of landings has a width of about 0.2 mm to about 0.3 mm.

9. The processed graphite plate of claim 6, wherein the ratio of the width of each of the plurality of landings to the depth of each of the plurality of embossed channels is about 1 :2 to about 2: 1.

10. The processed graphite plate of claim 2, wherein the processed graphite plate has a thickness of about 0.3 mm to about 7 mm.

11. The processed graphite plate of claim 1, wherein each of the at least one scored channels has a depth of about 0.3 mm to about 3 mm.

12. The processed graphite plate of claim 1, wherein each of the at least one scored channels has a depth of about 0.4 mm to about 1 mm.

13. The processed graphite plate of claim 1, wherein each of the at least one scored channels has a depth of about 0.5 mm to about 0.7 mm.

14. The processed graphite plate of claim 1, wherein the at least one scored channel is formed by one of blade cutting, laser ablation, routering, milling, or scooping.

15. The processed graphite plate of claim 1, wherein each of the at least one scored channels are in parallel.

16. The processed graphite plate of claim 1, wherein the scoring tool is a knife.

17. The processed graphite plate of claim 16, wherein the knife comprises multiple blades and each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.

18. A system for processing a graphite plate, the system comprising: a platform configured to hold the graphite plate; a scoring tool configured to create at least one scored channel in the graphite plate; and a guide system attached to the scoring tool and configured to move along the length of the graphite plate.

19. The system of claim 18, wherein the scoring tool is a ganged knife comprising multiple blades configured to rake the graphite plate.

20. The system of claim 19, wherein each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.

21. The system of claim 18, wherein the scoring tool is made from a single blade comprising multiple teeth configured to rake the graphite plate.

22. The system of claim 18, wherein the platform comprises multiple pores, and the system further comprises a vacuum pump configured to create a vacuum under the platform and to hold the graphite plate in position on the platform.

23. The system of claim 18, wherein the guide system is attached to the platform by a mechanical arm, wherein the mechanical arm is configured to hold the scoring tool and move to the guide system between a position adjacent to the platform and a position away from the platform.

24. The system of claim 18, wherein the scoring tool is a laser.

25. The system of claim 18, wherein the platform is configured to move the graphite plate across the scoring tool.

26. A method of processing a graphite plate, the method comprising: providing a graphite plate; providing a scoring tool; and forming at least one scored channel in the graphite plate by contacting the graphite plate with the scoring tool thereby causing graphite contained in the graphite plate to be deformed.

27. The method of claim 26, wherein the scoring tool is a ganged knife comprising multiple blades configured to rake the graphite plate.

28. The method of claim 26, wherein: the scoring tool is attached to a guide system; and, forming at least one scored channel comprises moving the scoring tool along the length of the graphite plate.

29. The method of claim 28, wherein forming the at least one scored channel comprises moving the scoring tool along the length of the graphite plate one time.

30. The method of claim 28, wherein forming the at least one scored channel comprises moving the scoring tool along the length of the graphite plate between 2 and 10 times.

31. The method of claim 26, wherein: the scoring tool is attached to a guide system; and, forming the at least one scored channel comprises moving the graphite plate along the scoring tool.

32. The method of claim 26, wherein forming the at least one scored channel in the graphite plate using the scoring tool comprises: contacting the graphite plate with the scoring tool; moving the scoring tool along the length of the graphite plate.

33. The method of claim 26 further comprising: providing an embossing tool; and embossing the graphite plate to form a processed graphite plate with embossed channels.

34. The method of claim 33, wherein the processed graphite plate has a thickness of about 0.3 mm to about 0.35 mm.

35. The method of claim 33, wherein each of the at least one scored channels has a width that is greater than or equal to about 5% of the width of the embossed channels.

36. The method of claim 33, wherein each scored channel has a depth that is greater than or equal to about 5% of the depth of a corresponding embossed channel.

37. The method of claim 33, wherein the embossed channels are formed in approximately the same location as the at least one scored channel.

38. The method of claim 33, wherein the processed graphite plate further comprises a plurality of landings between each of the embossed channels.

39. The method of claim 38, wherein each of the plurality of landings has a width of about 0.2 mm to about 0.6 mm.

40. The method of claim 38, wherein each of the plurality of landings has a width of about 0.2 mm to about 0.3 mm.

41. The method of claim 38, wherein the ratio of the width of each of the plurality of landings to the depth of each of the embossed channels is about 1 :2 to about 2: 1.

42. The method of claim 33, wherein the processed graphite plate has a thickness of about 0.3 mm to about 7 mm.

43. The method of claim 33, wherein each of the at least one scored channels has a depth of about 0.4 mm to about 3 mm.

44. The method of claim 33, wherein each of the at least one scored channels has a depth of about 0.4 mm to about 1 mm.

45. The method of claim 33, wherein each of the at least one scored channels has a depth of about 0.5 mm to about 0.7 mm.

46. The method of claim 26, wherein the forming the at least one scored channel is performed by one of laser ablation, routering, milling, or scooping.

47. The method of claim 26, wherein the each of the at least one scored channels are in parallel.

48. The method of claim 26, wherein the scoring tool is a knife.

49. The method of claim 48, wherein the knife comprises multiple blades and each of the multiple blades has an angled tip with an edge angle of about 30 degrees to about 70 degrees.

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