Method and press for introducing a deformation pattern into a metal sheet

Abstract

To provide a method for processing a deformation processing pattern on a metal sheet.SOLUTION: The reshaping pattern has, in at least one partial region, a plurality of identical pattern units which lie next to one another at a pattern spacing in at least one pattern direction, wherein the press comprises a tool unit for forming only the partial region, wherein at least one pattern unit of the partial region is formed in the metal sheet in a single stroke of the tool unit by the cooperating forming structures of the upper forming punch and the lower forming punch, the sheet metal is further transported in the tool unit between two successive strokes of a predefined total number of strokes of the tool unit, wherein each stroke of the predefined total number of strokes adds at least one processed pattern unit to the pattern formed in the sheet metal.SELECTED DRAWING: Figure 10

Description

[Technical Field]

[0001] The present invention relates to a method for producing a deformation pattern in a sheet metal, in particular made of metal, by means of at least one tool unit of a press.The present invention also relates to a press.

[0002] The provision of deformation patterns in metal sheets is widespread in the prior art. To this end, the desired deformation pattern in the sheet metal is provided in corresponding deformation structures in an upper and a lower deformation punch according to the prior art, so that the deformation pattern can be transferred to the sheet metal located between the punches by bringing the deformation punches together in a press. These punches are also called female and male dies. This principle is also used in the present invention. [Background technology]

[0003] One application area in which the present invention can also be advantageously used is the production of electrolyzer plates, in particular so-called "interconnectors" for electrolyzers, or fuel cell or bipolar plates. These plates often have deformed shapes, such as embossed and / or deep-drawn regions, as well as stamped regions, and are used in stacked configurations, for example, in electrolyzers or fuel cells. In this case, the deformed and / or stamped regions often define regions of the plate through which fluid is guided. Stamped regions often define regions that guide fluid between different planes of the plate stack, while deformed regions, such as embossed regions, define regions that guide fluid within, parallel to, or around one plane of the plate. Such plates may also have deformed or stamped regions that do not serve to guide fluid, for example, for assembly purposes. In such plates, so-called flow fields, which form partial regions of the overall deformation pattern, define particularly large regions where fluid-guiding channels or channel segments are connected in terms of their location. Therefore, the present invention is preferably used in the plates of an electrolyzer or fuel cell having such a flow field.

[0004] According to the prior art, at least the flow field region of such a plate is produced in a single stroke of a tool unit of a press, to which the precision cutting device preferably used in this case also belongs, and which advantageously can carry out both the forming and the punching in one stroke.

[0005] The problem is that as the size of the deformation pattern increases, or as the number of depressions / protrusions relative to the plane of the sheet metal increases, for example in electrolyzer plates or bipolar or fuel cell plates, the force required for deformation increases significantly, so that the desired deformation pattern can no longer be produced in one individual stroke on a conventional press. This problem is particularly acute with electrolyzer plates, since electrolyzer plates have a much larger surface than fuel cell plates.

[0006] The increasing trend in electrolyzer plates or bipolar / fuel cell plates means that even partial areas of the overall deformation pattern of such plates, such as the production of flow fields, can no longer be realized, or at least not in an economically feasible manner, or can no longer be realized with the required precision, on existing presses of the usual design. Summary of the Invention [Problem to be solved by the invention]

[0007] The object of the present invention is therefore to provide a method for forming a deformation pattern in sheet metal, which can be realized with conventional presses and tooling units used in such presses. In particular, it is desirable to develop a method for forming a flow field portion of the entire deformation pattern, preferably the entire deformation pattern, in particular together with the additional punchings, in conventional, commercially available presses, so that it is possible to produce the entire deformation pattern, in particular together with the additional punchings, in an economically efficient manner. In particular, it is desirable to improve or simplify the production of electrolyzer plates and / or fuel cell plates / bipolar plates. [Means for solving the problem]

[0008] This problem is solved by the following: in at least one partial region, the deformation pattern has a plurality of identical pattern units positioned next to each other at a predetermined pattern distance in at least one pattern direction; the press includes a tool unit for deforming only the partial region, in which an upper deformation punch and a lower deformation punch are arranged, and by the cooperating deformation structure of these deformation punches, at each stroke of the tool unit, at least one pattern unit of the partial region is formed into a metal sheet guided between the deformation punches; the metal sheet is further transported within the tool unit in a feed direction corresponding to at least one pattern direction between two consecutive strokes of a predetermined total number of strokes of the tool unit; and at least one pattern unit is added to the pattern being processed / formed into the metal sheet with each stroke of a predetermined total number of strokes in the tool unit until the partial region of the deformation pattern is completed after the predetermined total number of strokes. The tool unit may preferably include further tools which take part in the method in addition to the forming punch.

[0009] Preferably, individual strokes are understood to mean a succession of closing phases of the tool units, in which the deforming punches move towards each other, and opening phases of the tool units, in which the deforming punches move away from each other.

[0010] Deforming with the deforming punch is carried out, for example, by deep drawing and / or embossing of the sheet metal, which occurs during the closing phase of the tool unit, in particular by deep drawing followed by embossing, preferably in the same stroke of the tool unit.

[0011] The feeding of the sheet metal in the tool unit between the two strokes, in particular between the two closing phases, is preferably carried out by means of a feed device, in particular provided in the press or in the tool unit, which preferably causes the feeding of the sheet metal during and / or after the opening phase of one stroke.

[0012] The present invention utilizes or can be used in cases where the entire deformation processing pattern to be produced can be decomposed into multiple partial areas that can be produced one after the other, in which case the present invention aims to identify or define at least one partial area in the deformation processing pattern that can be divided into multiple identical pattern units, in which multiple pattern units are arranged so that they are located next to each other in the partial area, and the pattern units have a uniform pattern spacing relative to each other.

[0013] In particular in electrolyzer or fuel cell plates, such partial areas which can be divided into a plurality of pattern units can be formed by so-called flow fields, in which fluids can be guided in an electrolyzer or fuel cell made up of a plurality of such plates. Preferably, such electrolyzer or fuel cell plates contain, in addition to the flow fields, further deformed or stamped areas, which are in particular arranged outside and surrounding the flow fields.

[0014] In such a flow field, for example, certain pattern regions forming passageways may occur repeatedly side by side, each repeating pattern region forming one pattern unit within the meaning of the present invention.

[0015] In particular, it is preferred that the above-mentioned partial region only includes pattern units arranged side by side in only one pattern direction, and that only one feed device is provided by means of which the sheet metal is transported within the tool unit. However, as long as the partial region has pattern units arranged side by side in at least two pattern directions, for example, two pattern directions perpendicular to one another, it may also be provided that the sheet metal is further moved within the tool unit between two strokes in one of the at least two pattern directions or in a feed direction consisting of at least two pattern directions.

[0016] According to the invention, this method reduces the press force required for deformation, because with each stroke, only a small portion of the part area of ​​the deformation pattern that is repeated in this part area is processed or formed into the sheet metal. Therefore, even very large flow field arrangements in electrolyzer plates or bipolar / fuel cell plates can be produced with a relatively small press. This is very economically reproducible thanks to the invention, because the same pair of upper and lower deformation punches can always be used repeatedly in the same tool unit to deform such part areas until the entire part area is completed.

[0017] Therefore, as long as there are partial areas in the deformation pattern with a defined total number of pattern units, the invention provides for deformation of these partial areas with up to a corresponding maximum number of strokes, with each pattern unit being formed in one unique individual stroke.

[0018] In contrast, it is considered preferable that the cooperating deformation structure of the lower and upper deformation punches of the tool unit simultaneously form N pattern units of a partial area in each stroke of the tool unit, where N ≥ 2. Preferably, the number N is an integer greater than 15% of the total number of all pattern units provided in the partial area, more preferably greater than 20%.

[0019] Preferably, the maximum deformation force that can be generated in the tool unit determines the maximum number of all pattern units that can be formed in a single stroke in order to minimize the number of strokes required.

[0020] A preferred refinement provides that after one stroke of the tool unit, the metal sheet is further transported so that the processed pattern of the metal sheet, in particular the area of ​​the processed pattern formed in the previous stroke, is at least partially overlapped by the deforming structures of the upper deforming punch and the lower deforming punch.

[0021] This overlapping allows each additional stroke of the deforming punch after the first stroke to form a new area in the sheet metal that corresponds to the deforming structure of the deforming punch, except in the overlapping area. In the overlapping area, the sheet metal is actually formed twice, which, in particular, results in no or substantially no further forming. However, the overlapping preferably results in positioning of the sheet metal relative to the deforming punch, since the overlapping areas of the sheet metal that have already been formed are aligned with the deforming structure of the punch, thereby improving the accuracy of the positioning of the areas formed by each stroke relative to one another.

[0022] To achieve an overlap, for example, a thin metal sheet is further moved in the feed direction by M times the pattern pitch, where M < N, and N may be defined as corresponding to the number of pattern units that can be processed by the shaping punch. Thereby, preferably always, an overlap is formed that matches the N - M pattern units.

[0023] More preferably, by each stroke of the tool unit, a positioning geometry is machined into the thin metal sheet, and the tool unit or the press is provided with positioning elements, which are brought relative to each other into a predefined position relative to the positioning geometry before and / or by the closing movement of one stroke.

[0024] The closing movement of one stroke is a movement in which the upper shaping punch and the lower shaping punch are moved closer to each other.

[0025] The positioning geometry may preferably be a punched positioning aperture. The positioning element may preferably be a positioning pin that runs into the positioning aperture at least in a predefined region. The positioning pin may preferably be a component of the tool unit, in particular of one of the two shaping punches, or of at least one component of the press that is moved during the stroke.

[0026] Preferably, the position of machining the positioning geometry is located in a region of the thin metal sheet where the part of the partial region to be processed iteratively is not located.

[0027] This also offers the advantage of shaping or preferably punching the positioning geometry by a punch located adjacent to the shaping punch in the tool unit or the press. Similarly, the positioning element can be arranged adjacent to the shaping punch in the tool unit or the press.

[0028] Preferably, the locating opening is a circular hole, and the locating pin has a circular cross-section. Preferably, the pin, regardless of the cross-sectional shape, tapers toward its free end. In particular, the pin expands from its free end / tip to an outer cross-section / outer diameter that is greater than the inner cross-section / inner diameter of the locating opening. In this case, the pin cannot completely penetrate the locating opening, but centers the opening around its tip. This limits the penetration depth to the tapered tip region, which prevents the pin from getting stuck in the opening and / or facilitates retraction from the locating opening. Preferably, the locating pin is elastically supported in the axial direction of the stroke movement of the tool unit or press.

[0029] A preferred configuration provides that positioning geometries are respectively arranged in the region of the sheet metal where at least one stamping will be processed in a subsequent stamping step, in particular carried out by another tool unit in the same or another press, in which case at least one stamping removes at least one positioning geometry, preferably where the stamping has a function for guiding fluids in a stack of multiple electrolyzer or fuel cell plates. Preferably, the multiple stampings remove all previously produced positioning geometries. It is thus ensured that the positioning geometries are only temporary elements of the sheet metal during processing of the sheet metal, and that these temporary elements no longer exist in the later finished sheet metal.

[0030] Preferably, the positioning geometries may be located in the rear effective area of ​​the electrolyzer plate to be manufactured, but these positioning geometries are not obstructive since they are subsequently replaced by punchings required for the function of the electrolyzer plate, for example by punchings for guiding fluids. Preferably, it is always provided that the positioning geometries are located entirely within the cross-sectional area of ​​the punchings that remove and / or replace them. In particular, the punchings are therefore always larger than the positioning geometries.

[0031] It is preferably provided that the elements for machining the positioning geometry, in particular the punching punches, and the positioning elements are arranged in the tool unit at a distance in the feed direction which is smaller than the number of pattern units that can be machined by the deformation punches, in particular corresponding to M x the pattern spacing.

[0032] In particular, this spacing is thereby smaller than the width of the forming punch, seen in the feed direction of the sheet metal, the width of the forming punch being N times the pattern spacing.

[0033] The invention preferably provides for processing pattern parts of a deformation pattern into the sheet metal in or by means of at least one further tool unit and / or for processing punched parts and / or edge trimmings into the sheet metal which are not part of the partial area but are arranged in particular outside around the partial area.

[0034] The further tool unit may be arranged in the same press as the above-mentioned tool unit that repeatedly forms the partial area, in particular as a so-called progressive tool, or in a different press, or it may be provided that the tool unit that repeatedly forms the partial area is replaced in the same press by the above-mentioned further tool unit that forms pattern parts that are not part of the partial area.

[0035] In the latter case, the invention preferably provides for two tool units, with a first tool unit capable of forming a partial area with repeating pattern units and a second tool unit capable of forming a pattern portion of the deformation pattern that is not part of the partial area but is located on the periphery of the partial area, and the press is first equipped with one of the two tool units, in particular the first tool unit, and a number of sheet metals are formed with this tool and temporarily stored in a buffer, and then the other of the two tool units, in particular the second tool unit, is equipped to the same press, and the sheet metals are removed from the buffer and formed with this other tool unit. In this method, both tool units are used interchangeably in one press, and it is not particularly important which tool unit is used first.

[0036] At least one further tool unit may carry out processing earlier than the above-mentioned tool unit, but it is preferably provided that this further tool unit carries out processing of the metal sheet later than the forming of at least one partial area, in particular in this case the metal sheet is completed in just one stroke by the at least one further tool unit in addition to the total number of strokes for forming at least one partial area.

[0037] In this case, completion preferably simply means that further processing of the sheet metal by the press is no longer planned, although further processing may be planned in another processing station.

[0038] In particular, the metal sheet is removed from the press after it has been worked by at least one other tool unit of the same press.

[0039] It is considered advantageous if at least one further tool unit processes a stamping which completely covers the positioning geometry, in particular thereby eliminating the positioning geometry.

[0040] Thus, pre-machined positioning geometries are located in the areas that will be subsequently stamped out. In particular, stampings that will take on a predetermined function in the finished sheet metal, such as mounting and / or fluid guiding, are preferred if the finished sheet metal is to form an electrolyzer plate or a fuel cell / bipolar plate.

[0041] In particular, this refinement preferably provides that the aforementioned further tool unit is used chronologically after the tool unit for forming the aforementioned partial area.

[0042] In addition to the method, the invention also relates to a press with at least one tool unit, in particular characterised in that the method can be carried out by means of the press.

[0043] According to the present invention, the press includes at least one tool unit, which has an upper deforming punch and a lower deforming punch, and the cooperating deforming structure of the upper deforming punch and the lower deforming punch enables at least one pattern unit of a partial area of ​​a deforming pattern to be formed in the metal sheet in each stroke of the tool unit, the deforming pattern having a plurality of identical pattern units positioned next to each other at a predetermined pattern interval in at least one pattern direction, and the tool unit is configured to sequentially form the partial area to completion with a plurality of strokes.

[0044] Preferably, the cooperating deformation structures provide that in each stroke, several pattern units of a partial area can be processed.

[0045] In this case, this is understood to mean that, according to the invention, in each stroke, not all pattern units are formed simultaneously, but only a partial number of all pattern units.

[0046] Preferably, the press, in particular the tool unit of the press, has a feed device by means of which the sheet metal can move further within the tool unit between successive strokes, in particular by at least a predetermined pattern spacing, preferably by multiple times the pattern spacing.

[0047] In one possible configuration, the same press has, in addition to the aforementioned tool units, at least one other tool unit, in particular just one other tool unit, by means of which pattern sections of the deformation pattern that are not part of the partial area, in particular arranged outside the periphery of the partial area, can be formed and / or stamped into the sheet metal. Preferably, with just one other tool unit, the deformation pattern in the sheet metal or the entire sheet metal, in particular an electrolyzer plate or a fuel cell plate, can be completed, preferably in just one stroke. In this case, at least two tool units form a progressive tool for the press, between which the sheet metal can be further moved within the press.

[0048] Another configuration also provides that in the press, the tool unit that forms the pattern unit of the partial area can be replaced with another tool unit, by means of which pattern parts that are not part of the partial area but are arranged, in particular, around the partial area, can be formed into the metal sheet.

[0049] Preferably, the press for producing the electrolyzer plate or fuel cell plate may, in one possible configuration, have several / at least two tool units, with each of which different partial areas consisting of the same pattern unit are formed or at least can be formed.

[0050] Such a press may, in a variant, also have further tooling units for forming and / or stamping all remaining parts of the sheet metal, in particular the electrolyzer plate or fuel cell plate.

[0051] The invention will now be described with reference to the drawings in relation to a preferred embodiment during the manufacture of a fuel cell plate or electrolyzer plate. [Brief explanation of the drawings]

[0052] [Figure 1A] 1 is a diagram showing a horizontal cross section of a tool unit W1 of a press P. FIG. [Figure 1B] 1B is a diagram showing cross sections AA and BB taken along lines AA and BB shown in FIG. 1A in an open state, together with enlarged detailed views of these cross sections. [Figure 1C] 1B is a diagram showing a cross section AA along line AA and a cross section BB along line BB shown in FIG. 1A in a closed state, together with enlarged detailed views of these cross sections. [Figure 2A] 1 shows the same situation for a subsequent second stroke of tool unit W1 after the first stroke has been performed and the sheet metal 1 has been further moved in feed direction 6.2, which corresponds to the pattern direction. [Figure 2B] 2B is a diagram showing cross sections AA and BB taken along lines AA and BB shown in FIG. 2A in an open state, together with enlarged detailed views of these cross sections. [Figure 2C] 2B is a view showing a cross section AA along line AA and a cross section BB along line BB shown in FIG. 2A in a closed state, together with enlarged detailed views of these cross sections. [Figure 3A] A diagram showing the repetition of strokes, the repetition of positioning of the metal sheet 1 at the pin 4 by the positioning geometry 5.1 with each stroke, and the machining of each new positioning geometry 5.1 with the punch 5. [Figure 3B] 3B is a diagram showing cross sections AA and BB taken along lines AA and BB shown in FIG. 3A in an open state, together with enlarged detailed views of these cross sections. [Figure 3C] 3B is a diagram showing a cross section AA along line AA and a cross section BB along line BB shown in FIG. 3A in a closed state, together with enlarged detailed views of these cross sections. [Figure 4A] A diagram showing the repetition of strokes, the repetition of positioning of the metal sheet 1 at the pin 4 by the positioning geometry 5.1 with each stroke, and the machining of each new positioning geometry 5.1 with the punch 5. [Figure 4B] 4B is a diagram showing a cross section AA taken along line AA and a cross section BB taken along line BB shown in FIG. 4A in an open state, together with enlarged detailed views of these cross sections. [Figure 4C] 4B is a diagram showing a cross section AA taken along line AA and a cross section BB taken along line BB shown in FIG. 4A in a closed state, together with enlarged detailed views of these cross sections. [Figure 5A] Yet another diagram showing the repetition of strokes, the repetition of positioning of the metal sheet 1 at the pin 4 by the positioning geometry 5.1 with each stroke, and the machining of each new positioning geometry 5.1 with the punch 5. [Figure 5B] 5B is a diagram showing cross sections AA and BB taken along lines AA and BB shown in FIG. 5A in an open state, together with enlarged detailed views of these cross sections. [Figure 5C]5B is a diagram showing a cross section AA along line AA and a cross section BB along line BB shown in FIG. 5A in a closed state, together with enlarged detailed views of these cross sections. [Figure 6] FIG. 10 is a diagram showing the final result of deformation machining by the tool unit W1. [Figure 7] 1 is a perspective view showing a product manufactured from a flat metal sheet 1. FIG. [Figure 8] Detail view showing a product manufactured from flat sheet metal 1. FIG. [Figure 9] 1 is a schematic symbolic view of a press P according to the invention for carrying out the method; [Figure 10] 1 is a diagram showing a configuration in which a tool unit W1 is first used in a press machine P. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0053] Figures 7 and 8 discussed earlier in this specification show in overview perspective or detailed view products made from flat sheet metal 1, in this case electrolyzer plates or bipolar plates or fuel cell plates, from which in particular further plates and elements can be stacked together to form an electrolyzer or fuel cell.

[0054] 7 and 8, the fully manufactured sheet metal 1 has a deformation pattern, in particular also having further processes in addition to the deformation pattern, such as stamped sections and edge-trimmed areas. This applies in particular to all sheet metal 1 manufactured according to the invention, even in addition to the preferred application in the manufacture of electrolyzer plates or bipolar / fuel cell plates. In all configurations of the invention, the deformation pattern is imparted by all protrusions and / or recesses relative to the plane of the original, not yet deformed, sheet metal 1. The deformation pattern is produced by deformation of the sheet metal 1, for example by deep drawing and / or embossing.

[0055] Such ridges and / or recesses of the deformation pattern fulfill different functions in the formed metal sheet 1. In preferred applications, the ridges and / or recesses can, for example, form support structures via which adjacent metal sheets 1 / electrolyzer plates / bipolar plates are supported against one another or against other elements of the stack. The ridges and / or recesses can also form, for example, sealing regions, in particular at the edges of the deformed and preferably cut metal sheet 1. Particularly important, and in particular the largest, areas of the deformation pattern are here formed by the ridges and / or recesses which form the so-called flow fields of the electrolyzer or bipolar / fuel cell plates or metal sheet 1.

[0056] In the illustrated configuration, the flow field includes a plurality of elongated passages 6, all identically formed and positioned side by side at equal intervals perpendicular to their longitudinal extension. In configurations other than that shown, the flow field may have a different geometric shape. The invention, even in its preferred application in electrolyzer plates or fuel cell / bipolar plates, is not limited to the specifically illustrated flow field. In particular, the flow field may have other passage shapes and / or passage sections, but according to the invention has a periodicity of one pattern unit in the flow field.

[0057] The overall deformation pattern to be processed in the sheet metal 1 by the press P, in particular by at least one tool unit of the press P, has subregions forming flow fields in this preferred application. These subregions are advantageously arranged such that the pattern units 6.1 are arranged next to each other multiple times in at least one pattern direction 6.2 (here, only one pattern direction), and all adjacent pattern units 6.1 have the same pattern spacing 6.3. This relationship is evident from the detailed view of FIG. 8. The pattern in the subregions therefore has a repetitive or periodic nature corresponding to the pattern spacing 6.3. In the case of this electrolyzer plate or bipolar plate, the smallest pattern unit 6.1 in the subregion is an individual channel 6. The pattern spacing 6.3 is the spacing between two adjacent channels 6 or two pattern units 6.1.

[0058] Due to the large number of protrusions and / or depressions that must be produced in the largest areas of the sheet metal 1, such flow fields cannot be produced by individual strokes of the tooling units of the press P, or can only be produced with economically unreasonable effort, since the press P would have to be dimensioned too large for this production.

[0059] The present invention aims to repeatedly form such partial regions of the overall deformation pattern, which can be decomposed into identical pattern units 6.1, by identical strokes performed successively on one and the same tool unit W1 and by the same pair of two deformation punches 2, 3, which always move opposite each other in the stroke direction. Between these deformation punches 2, 3, the sheet metal 1 is further moved in a feed direction corresponding to the pattern direction 6.2. The further movement, for example by a feed device acting on the sheet metal, is carried out with the deformation punches 2, 3 spaced apart so that a gap is formed between them. In this case, the pattern direction 6.2 is the direction in which the pattern units 6.1 are arranged side by side. In this configuration, the pattern direction 6.2 is perpendicular to the longitudinal extension of the passages 6 and / or parallel to the longitudinal extension of the sheet metal 1.

[0060] Figure 1 shows the cooperating components of the tool unit W1 during the first stroke after the sheet metal 1 to be formed, preferably a sheet metal 1 that has not yet been deformed, has been moved into the tool unit W1 in a feed direction corresponding to the pattern direction 6.2, in particular by a feed device acting on the sheet metal 1.

[0061] FIG. 1A shows a horizontal cross section of a tool unit W1 of a press P, in an open state of the tool unit W1, for example, where the deforming punches 2 and 3 are spaced apart so that the metal sheet 1 can move between them, and shows other elements in a different plane parallel to the cutting plane, viewed from above, together with the metal sheet 1 located within the tool unit W1.

[0062] For example, Fig. 1A shows in dashed lines a feeder F, which preferably acts on the metal sheet 1 on both sides thereof in order to move the metal sheet 1. The exemplary illustration of the feeder F chosen in Fig. 1A is not intended to limit the invention. The feeding of the metal sheet 1 can also be achieved by other arrangements of the feeder F.

[0063] In the open state, Figure 1B shows the cross sections AA and BB shown in Figure 1A, along with enlarged details of these cross sections. Figure 1C shows the cross sections AA and BB shown in Figure 1A, along with enlarged details of these cross sections, in the closed state. In this closed state, the deforming punches 2 and 3 have been moved closer to each other, so that the deformed structures of the deforming punches 2 and 3 can be transferred to the metal sheet 1.

[0064] Here, section AA preferably shows a section passing through the deforming punches 2, 3 at the center, and section BB shows an area located next to the deforming punches 2, 3, shifted laterally in a direction perpendicular to the feed direction.

[0065] The upper and lower deforming punches 2 and 3 have corresponding (particularly negative) deformation structures. These deformation structures allow a number N of pattern units 6.1, i.e., passages 6 for example, to be simultaneously formed in the sheet metal 1 with one stroke. These passages 6 are open in one direction perpendicular to the plane of the sheet metal. The number N of pattern units 6.1 that can be simultaneously formed in the sheet metal 1 with one stroke by the deforming punches 2 and 3 is smaller than the total number of all pattern units 6.1 located in a subregion of the deformation pattern, i.e., in the flow field. In this embodiment, 14 pattern units 6.1 can be simultaneously formed. This number is not a limitation of the invention and can basically take any value, in particular smaller than the total number of pattern units 6.1 in the subregion, preferably greater than 1.

[0066] In addition to the deforming punches 2 and 3, which are movable toward and away from each other in the stroke direction, the tool unit W1 also has rods 7. These rods 7 allow the sheet metal 1 to be fixed in a predetermined position within the tool unit W1 during deformation. Such rods 7 may preferably be arranged around the deforming punches 2 and 3.

[0067] Displaced laterally in a direction perpendicular to the feed direction 6.2 next to the forming punches 2, 3 and thus next to the pattern to be machined in the partial area, a punch punch 5 is provided as the element for machining the positioning geometry, and a pin is provided as the positioning element 4. The punch punch 5 and the positioning element 4 preferably form further tools of the tool unit W1 in addition to the forming punches 2, 3.

[0068] During the first stroke of tool unit W1, pin 4 cannot yet enter the hole punched by punch punch 5, thereby achieving positioning. In contrast, sheet metal 1 may be run up to pin 5, for example, until it contacts pin 4, during its initial movement into tool unit W1. Preferably, during the first stroke, the positioning of the pattern unit 6.1 to be machined / formed is not critical, since there is no reference in sheet metal 1 to which the initial deformation must be aligned. Rather, the cooperation of pin 5 and positioning geometry 5.1 punched by punch punch 5 serves to align the subsequent forming of pattern unit 6.1 with the previously formed pattern unit 6.1, as will be explained further below.

[0069] The lower detail of Figure 1B shows the arrangement of the as-yet-unformed sheet metal 1 between the deforming punches 2, 3, while the upper detail shows that the sheet metal 1 has been brought up to the pin 4. In this position of the sheet metal 1, a first stroke is carried out by the tool unit W1, i.e. the sheet metal 1 is clamped by the rod 7 and the deforming punches 2, 3 are moved towards each other, whereby the deformed structure of the deforming punches 2, 3 is transferred to the sheet metal, whereby N (preferably N > 1) pattern units 6.1 are formed simultaneously, in this example 14 pattern units 6.1 are formed.

[0070] 1C shows the closed position of the tool unit W1. During the stroke of machining or forming all N pattern units 6.1 of the partial area, locating holes are simultaneously machined into the sheet metal 1 as locating geometries 5.1, which are offset laterally next to the deformations being made into the sheet metal 1.

[0071] 2 shows the same situation for a subsequent second stroke of the tool unit W1 after the first stroke has been performed and the sheet metal 1 has been further moved in the feed direction 6.2, which corresponds to the pattern direction, so that the already formed area is moved next to the forming punches 2, 3 in at least a certain area in the feed direction.

[0072] In particular, the lower detailed view of Figure 2B shows that, when the tool unit W1 is in the open state, the previously created deformation portion is not moved completely next to the deformation punches 2, 3 by further moving the metal sheet 1, but rather, by further transporting the metal sheet after one stroke of the tool unit W1, the area of ​​the formed pattern formed by the preceding stroke and delayed in the feed direction is made to overlap the deformation structures of the upper and lower deformation punches.

[0073] Furthermore, the upper detail shows that after further transport of the sheet metal 1, the pins 4 overlap the stamped positioning geometry 5.1.

[0074] Therefore, from the second stroke onwards, and for each subsequent stroke, the closing of the tool unit W1 during the stroke causes the tapered extending pin 4 to run into the positioning geometry 5.1, as shown in FIG. 2C, so that the positioning geometry 5.1 is preferably centred around the tapered free end of the pin 4, thereby positioning the metal sheet 1, in particular before the deforming punches 2, 3 are completely closed.

[0075] In addition to the overlap occurring between the deforming structures of the deforming punches 2, 3 and the partial regions of the N pattern units that are delayed in the feed direction of the forming sections produced in the preceding stroke, a very high relative positioning accuracy of the deformation sections to be added to the preceding deformation sections by a stroke is achieved. It should be noted that the overlap shown in the drawing is not necessarily required, since sufficient positioning is already achieved by the cooperation of the pin 4 and the positioning geometry 5.1.

[0076] 2B makes it clear that in this example, the deformation structures of the deformation punches 2, 3 overlap with some of the preceding deformations, here in particular four pattern units. The movement of the sheet metal 1 after one stroke therefore takes place by M pattern units, where M is smaller than the number N of pattern units that have been processed / formed or at least can be processed / formed in the preceding stroke. In the example shown, N=14 and M=10, resulting in an exemplary overlap of N=4 pattern units.

[0077] Therefore, in the subsequent second stroke, again N (14) pattern units are formed. However, M (10) of the N (14) pattern units are newly formed, and N - M (4) pattern units, that is, the four pattern units 6.1 located within the overlap, are formed twice. Depending on the movement distance of the sheet metal 1 between the two strokes, the distance between the pin 4 and the punch 5 that processes the positioning geometry 5.1 is determined. This distance is here M × pattern pitch.

[0078] According to the described functional form, in the first stroke, N pattern units 6.1 are formed in the sheet metal 1. In this case, after moving the sheet metal further by M (where M < N) pattern units, that is, when there is an overlap of N - M pattern units, in each subsequent stroke, until the forming of the partial region of the deformation pattern is completed in the last stroke, only M pattern units are added to the pattern formed in the sheet metal 1.

[0079] Therefore, the predefined total number of pattern units 6.1 to be formed in the partial region of the deformation pattern can always be divided into an integer number of strokes by the number of pattern units 6.1 that can be formed by the pair of deformation punches 2, 3 and the selected overlap. Therefore, the overlap serves only supplementarily to improve the accuracy and can be preferentially used to divide the total number of pattern units in a significant form by multiple strokes.

[0080] The following FIGS. 3 to 5 show the repetition of the strokes, the repetition of the positioning of the sheet metal 1 at the pin 4 by the positioning geometry 5.1 associated with the repetition of the strokes, and the machining of a new positioning geometry 5.1 performed by using the punching punch 5 in each stroke.

[0081] Figure 6 shows the final result of the deformation process with the tool unit W1 after the subregions T of the deformation pattern have been formed sequentially with a predefined number of strokes. Thus, according to Figure 6, a flow field consisting of a number of channels 6 is formed, which is laterally surrounded by the positioning geometry 5.1 created during the deformation process.

[0082] With the aid of at least one further tool unit W2, the remaining parts of the deformation pattern, in particular the deep-drawn areas or embossments, are now produced surrounding the previously shaped partial areas T. Additionally, with the aid of at least one further tool W2, preferably just one further tool unit W2, punched areas 8 and / or edge trimmings 9 and / or support geometries 10 and / or sealing channels 11 can be produced in the sheet metal 11 in a single stroke.

[0083] Preferably, the arrangement of at least some of the punched portions 8 which serve as flow passages for fluids in the electrolyzer or fuel cell is positioned so that these punched portions 8 remove the previously machined positioning geometry 5.1 again.

[0084] FIG. 9 shows symbolically a schematic view of a press P according to the invention for carrying out the method.

[0085] The press P includes at least one first tool unit W1 in which a subregion of a deformation pattern is worked or formed into the sheet metal 1 by multiple repeated strokes of the same pair of two deformation punches. The deformation pattern has repeating pattern units 6.1 positioned side by side. After multiple strokes completing a subregion, the sheet metal 1 is transferred from the first tool unit W1 to a second tool unit W2 of the press. The second tool unit W2 is part of the same press P that also includes the first tool unit W1.

[0086] In the tool unit W2, which removes the repeatedly formed sheet metal 1 from the tool unit 1, the deformation pattern of the sheet metal 1 is preferably completed in just one additional stroke, i.e., all additional deformation operations planned for the partial areas are performed. Additionally, additional punching or cutting operations can be performed on the sheet metal in the same stroke. However, the invention can also provide that the additional processing of the sheet metal 1 is distributed to several tool units W2 after the tool unit W1, for example, one additional tool unit W2 performs the remaining deformation operations and yet another tool unit W2 performs the punching and / or edge trimming.

[0087] The tool units W1, W2 may alternatively be operated in different presses or may be operated interchangeably in succession in the same press.

[0088] 10 visualizes a configuration in which the tool unit W1 is first used in the press P. The sheet metal 1 fed to the press P is first shaped solely by the tool unit W1, i.e., partial regions are successively shaped as defined by the present invention. The shaped sheet metal 1 is then fed to a buffer 12.

[0089] After forming a predetermined number of metal sheets 1, the tool unit W1 is exchanged in the press P for a tool unit W2, which is capable of forming into the metal sheet pattern parts that are not part of the produced partial region T. After this exchange, the previously formed metal sheet 1 is removed from the buffer 12 and fed back into the press P, so that it can be formed, in particular finished, by the tool unit W2.

Claims

1. 1. A method for producing a deformation pattern in a metal sheet (1) by means of at least one tool unit (W1) of a press (P), in particular for producing electrolyzer plates or fuel cell plates, comprising: a) the deformation pattern has, in at least one partial region (T), a plurality of identical pattern units (6.1) positioned next to each other in at least one pattern direction (6.2) at a predetermined pattern spacing (6.3); b) the press (P) comprises a tool unit (W1) for deforming only the partial region (T), in which an upper deforming punch (2) and a lower deforming punch (3) are arranged, and by means of the cooperating deforming structures of the deforming punches (2, 3), at each stroke of the tool unit (W1) at least one pattern unit (6.1) of the partial region (T) is formed into the sheet metal (1) guided between the deforming punches (2, 3); c) further transferring the sheet metal (1) within the tool unit (W1) in a feed direction corresponding to at least one pattern direction (6.2) between two consecutive strokes of the tool unit (W1) out of the total number of strokes of the predetermined number of strokes, d) Adding at least one pattern unit (6.1) to the pattern being machined in the sheet metal (1) with each stroke of the tool unit (P1) in a predetermined number of strokes until a partial area (T) of the deformation pattern is completed after a predetermined number of strokes; e. With each stroke of the tool unit (W1), a positioning geometry (5.1) is machined in the sheet metal (1), in particular a positioning opening is punched, and the tool unit (W1) or the press (P) is provided with a positioning element (4), in particular a positioning pin, which brings the positioning element (4) and the positioning geometry (5.1) into a predefined position relative to each other before and / or during the closing movement of one stroke, in particular the positioning pin (4) runs into the positioning opening (5.1), and f) positioning the positioning geometric shapes (5.1) in the respective areas of the sheet metal (1) where at least one stamping feature (8) will be produced in a subsequent stamping step, in particular by another tool unit (W2) of the same press (P) or another press (P), in particular by means of which at least one stamping feature is removed, preferably where the stamping feature (8) has the function of guiding a fluid in a stack of several electrolyzer or fuel cell plates; A method characterized by:

2. 2. The method according to claim 1, characterized in that, by the cooperating deformation structure of the lower deformation punch (2) and the upper deformation punch (3) of the tool unit (W1), N pattern units of the partial area T are simultaneously machined in each stroke of the tool unit (W1), where N≧2.

3. 3. The method according to claim 2, characterized in that after one stroke of the tool unit (W1), the sheet metal (1) is further transported so that the processed pattern of the sheet metal (1), in particular the area of ​​the processed pattern formed in the preceding stroke, is at least partially overlapped by the deforming structures of the upper deforming punch (2) and the lower deforming punch (3).

4. 4. The method according to claim 2 or 3, characterized in that the metal sheet (1) is further moved in the feed direction by M times the pattern spacing (6.3), where M<N.

5. 5. The method according to claim 1, wherein in the tool unit (W1), the elements (5) for machining the positioning geometry (5.1), in particular the punches (5), and the positioning elements (4) are arranged at a distance in the feed direction, the distance being smaller than the number of pattern units (6.1) that can be machined by the deformation punches (2, 3), in particular corresponding to M x pattern spacing (6.3).

6. 6. The method according to claim 1, further comprising processing pattern portions of the deformation pattern in the sheet metal (1) that are not part of the partial area (T), in particular arranged outside the periphery of the partial area (T), and / or processing stamped portions (8) and / or edge trimmings (9) in the sheet metal (1) in at least one other tool unit (W2) of the same press (P) or of a different press.

7. 7. The method according to claim 6, characterized in that the at least one further tool unit (W2) performs machining of the metal sheet (1) after the machining of at least one partial area (T), in particular completing the metal sheet (1) with the at least one further tool unit (W2) in just one stroke additional to the total number of strokes for machining the at least one partial area (T).

8. 8. The method according to claim 6 or 7, characterized in that the stamping (8) is machined into the sheet metal (1) by means of the at least one further tool unit (W2), the stamping (8) completely covering the positioning geometry (5.1), in particular thereby removing the positioning geometry (5.1).

9. A press (P) for carrying out the method according to any one of claims 1 to 8, The press (P) includes at least one tool unit (W1), which has an upper deforming punch (2) and a lower deforming punch (3), and the cooperating deforming structures of the deforming punches (2, 3) allow at least one pattern unit (6.1) of a partial region (T) of a deforming pattern to be processed in the sheet metal (1) to be processed in each stroke of the tool unit (W1), and the partial region (T) is formed by at least one pattern unit (6.1). The tool unit (W1) has a plurality of identical pattern units (6.1) arranged next to each other at a predetermined pattern spacing (6.3) in a direction (6.2), the tool unit (W1) being configured to form a partial area (T) successively to completion by a plurality of strokes, the tool unit (W1) being capable of forming a positioning geometric shape (5.1) in the sheet metal (1) with each stroke of the tool unit (W1), in particular punching a positioning opening, the tool unit (W1) or the press (P) being capable of forming a positioning geometric shape (5.1) in the sheet metal (1).

1. A press (P) according to claim 1, wherein the press (P) is provided with positioning elements (4), in particular positioning pins, such that before and / or by the closing movement of one stroke, the positioning elements (4) and the positioning geometries (5.1) can be brought into a predefined position relative to one another, in particular the positioning pins (4) can be inserted into the positioning openings (5.1), and the tool unit (W1) is configured to respectively position the positioning geometries (5.1) in areas of the sheet metal (1) where at least one stamping feature (8) can be processed in a subsequent stamping step, which can be carried out in particular by another tool unit (W2) of the same press (P) or another press, in particular by means of which the at least one positioning geometries (5.1) can be removed, and preferably the stamping feature (8) has the function of guiding a fluid in a stack of several electrolyzer plates or fuel cell plates.

10. 10. The press according to claim 9, characterized in that the press, in particular the tool unit (W1) of the press, has a feed device (F) by means of which the sheet metal can be further moved in the tool unit (W1) between successive strokes, in particular by at least a predetermined pattern spacing (6.3), in particular by a multiple of the pattern spacing (6.3).

11. a) the press has at least one further tool unit (W2), in particular as a progressive tool, by means of which, preferably in a single stroke, a pattern portion of the deformation pattern can be machined into the sheet metal (1) that is not part of the part area (T), in particular arranged outside the periphery of the part area (T), and / or a stamped portion (8) and / or an edge trimming (9) can be machined into the sheet metal (1), or 11. A press according to claim 9 or 10, characterized in that the tool unit (W1) provided in the press (P) for forming the partial region (T) of the deformation pattern can be replaced by another tool unit (W2) by means of which, preferably in a single stroke, a pattern portion of the deformation pattern that is not part of the partial region (T), in particular that is arranged outside the periphery of the partial region (T), can be machined into the metal sheet (1) and / or a stamped portion (8) and / or an edge trimming (9) can be machined into the metal sheet (1).

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