Systems and methods for preparing embossed graphite-based webs
The multi-roll calendering process integrates embossing and cutting without intermediate heating, addressing inefficiencies in existing methods to produce high-quality bipolar plate structures with reduced energy consumption and costs.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-02-02
- Publication Date
- 2026-03-10
AI Technical Summary
Existing methods for preparing embossed and cut graphite-based webs for bipolar plates are inefficient and require separate heating and cooling steps, leading to increased energy consumption and operational costs.
A multi-roll calendering process that integrates embossing and cutting without intermediate heating, using calendering and treatment rollers to directly transform untreated webs into treated webs with bipolar plate structures, eliminating the need for additional heating units between rollers.
Reduces energy usage, capital expenditures, and operational costs while producing high-quality, defect-free bipolar plate structures with improved consistency and reduced stress values.
Smart Images
Figure 2026508121000001_ABST
Abstract
Description
[Technical Field]
[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Application No. 63 / 442,895, filed February 2, 2023, the entire contents of which are incorporated herein by reference. [Background technology]
[0002] Bipolar plates are key components of fuel cells, distributing fuel and air, conducting electrical current, and removing heat generated in the cell's reaction zone. Bipolar plates are also useful in other applications, such as when used as separators in redox flow batteries.
[0003] Embossing and cutting of graphite-based webs is traditionally performed as a separate process separate from the multi-roll calendering (MRC) process, with the web being cooled after the calendering process and subsequently heated prior to embossing and / or cutting.
[0004] Despite the commercial success of the two-step process to date, there remains a need for improved and efficient methods for preparing embossed and cut graphite-based webs having bipolar plate structures. Summary of the Invention
[0005] In some aspects, the technology described herein relates to a multi-roll method for preparing a treated web having a bipolar plate structure, the method including: providing a multi-roll calender system including one or more calendering rollers and one or more treatment rollers, the system not including any heating unit disposed between the calendering rollers and the embossing roller; outputting an untreated web from the calendering rollers; and inputting the untreated web into the treatment rollers to prepare a treated web having a bipolar plate structure, the one or more treatment rollers including one or more cutting rollers, one or more embossing rollers, and / or one or more combination rollers.
[0006] In some aspects, the technology described herein relates to a multi-roll system for preparing a treated web having a bipolar plate structure, the system including one or more calendering rollers and one or more treatment rollers, the system not including any heating unit disposed between the calendering rollers and the treatment rollers, and the one or more treatment rollers including one or more cutting rollers, one or more embossing rollers, and / or one or more combination rollers.
[0007] In some aspects, the technology described herein relates to a treated graphite-based web having a bipolar plate structure prepared by a multi-roll process, the method including: providing a system including one or more calendering rollers and one or more treatment rollers, the system not including any heating unit disposed between the calendering rollers and the treatment rollers; outputting an untreated graphite-based web from the calendering rollers; and inputting the untreated graphite-based web into the treatment rollers to prepare a treated graphite-based web having a bipolar plate structure, the one or more treatment rollers including one or more cutting rollers, one or more embossing rollers, and / or one or more combination rollers. [Brief explanation of the drawings]
[0008] Aspects, features, benefits, and advantages of the embodiments described herein will become apparent with regard to the following description, the appended claims, and the accompanying drawings.
[0009] [Figure 1] A system is shown with seven calendering rollers 100 and two embossing rollers 200, with no heating unit 300 positioned between them. The arrows and dark curved arcs indicate the material path through the system rollers.
[0010] [Figure 2] The system is shown with different zones, which in turn include a melting zone 400, a kneading zone 500, a cooling / tempering zone 600, and an embossing zone 700.
[0011] [Figure 3] A system is shown having a heating unit 300 positioned between the calendering roller 100 and the embossing roller 200 . DETAILED DESCRIPTION OF THE INVENTION
[0012] This disclosure is not limited to the particular systems, devices, and methods described, as these may vary, and the terminology used herein is for the purpose of describing particular variations or embodiments only, and is not intended to limit the scope.
[0013] "Calendering roller" refers to a roller that applies one or more of heat, pressure, shear, or other physical conditions to a web of graphite film. A system may have one or more calendering rollers, or two or more calendering rollers. Calendering rollers are typically paired and force the material through a controlled gap to reduce the material to a predetermined thickness or density.
[0014] "Heating unit" refers to a device that raises the temperature of the raw web before it contacts the converting rollers.
[0015] system
[0016] In one example of the present technology, a system that can be used to prepare a treated web having a bipolar plate structure is described. In some examples, the treated web having a bipolar plate structure is a treated graphite-based web having a bipolar plate structure made from a graphite web / film. In some embodiments, the treated web comprises one or more embossed bipolar plate structures. In one embodiment, the treated web comprises one or more cut bipolar plate structures. The system may include one or more calendering rollers and one or more treatment rollers. The system does not include any heating unit disposed between the calendering roller and the treatment roller. In some embodiments, the one or more treatment rollers are positioned adjacent to the one or more calendering rollers. The system is configured such that the output of the calendering roller (untreated web) becomes the input of the treatment roller without being exposed to or contacting a heating unit located after the calendering roller but before the treatment roller. The system is not configured to heat the output of the calendering roller before it becomes the input of the treatment roller. The output of the treatment roller is a treated web having at least one bipolar plate structure. In some embodiments, the one or more processing rollers include one or more embossing rollers. In some embodiments, the one or more processing rollers include one or more cutting rollers. In still further embodiments, the processing rollers include one or more rollers that both cut and emboss the web as the rollers contact the web during operation. Such rollers that both cut and emboss the web are called combination rollers.
[0017] In some embodiments, the one or more embossing rollers include at least one embossing roller with a male embossing feature and at least one embossing roller with a female embossing feature, hi some embodiments, the male embossing feature and the female embossing feature are configured to align as the web passes between the embossing rollers.
[0018] The system may be configured so that the temperature of the output of the calendering rollers is higher than or the same as the temperature of the input of the processing rollers. The system may be configured so that the temperature of the output of the calendering rollers does not drop below the temperature of the input of the processing rollers. In some examples, the system is configured so that the output of the calendering rollers proceeds directly to become the input of the processing rollers without additional processing.
[0019] The number of calendering rollers and processing rollers can generally be any number. The number of calendering rollers and processing rollers can generally be any positive non-zero integer. The number of calendering rollers and processing rollers can be the same or different. For example, the number of calendering rollers can be two or more, such as two, three, four, five, six, seven, eight, or more calendering rollers. For example, the number of processing rollers can be two or more, such as two, three, four, five, six, seven, eight, or more processing rollers. In some specific examples, the number of processing rollers can be two (a pair of processing rollers).
[0020] In some embodiments, the one or more processing rollers include one or more embossable rollers. The number of embossing rollers can generally be any number. The number of embossing rollers can generally be any positive non-zero integer. The number of embossing rollers can be the same as or different from the number of calendering rollers. For example, the number of embossing rollers can be two or more, such as two, three, four, five, six, seven, eight, or more embossing rollers. In some particular examples, the number of embossing rollers can be two (a pair of embossing rollers).
[0021] In some embodiments, the one or more processing rollers include one or more cutting rollers. The number of cutting rollers can generally be any number. The number of cutting rollers can generally be any positive non-zero integer. The number of cutting rollers can be the same as or different from the number of calendering rollers. For example, the number of cutting rollers can be two or more, such as two, three, four, five, six, seven, eight, or more embossing rollers. In some particular examples, the number of cutting rollers can be two (a pair of cutting rollers).
[0022] In some embodiments, the one or more processing rollers include one or more combination rollers. The number of combination rollers can generally be any number. The number of combination rollers can generally be any positive non-zero integer. The number of combination rollers can be the same as or different from the number of calendering rollers. For example, the number of combination rollers can be two or more, such as two, three, four, five, six, seven, eight, or more combination rollers. In some particular examples, the number of combination rollers can be two (a pair of combination rollers).
[0023] In some embodiments, the one or more cutting or combining rollers include at least one cutting or combining roller with a male cutting feature and at least one cutting or combining roller with a female cutting feature, hi some embodiments, the male and female cutting features are configured to align as the web passes between the cutting or combining rollers.
[0024] In some embodiments, the one or more processing rollers include one or more cutting rollers and one or more embossing rollers. In some embodiments, the one or more cutting rollers are positioned before the one or more embossing rollers. In some embodiments, the system is configured such that the output of one or more cutting rollers is the input of one or more embossing rollers. In some embodiments, the one or more embossing rollers are positioned before the one or more cutting rollers. In some embodiments, the system is configured such that the output of one or more embossing rollers is the input of one or more cutting rollers. Similarly, one or more combination rollers may be provided before, between, or after the cutting rollers or embossing rollers, such that the output of one roller or group of rollers can be the input of the next roller or group of rollers.
[0025] The calendering rollers may be organized into one or more sets or zones. For example, there may be a melting zone, a kneading zone, and a cooling / tempering zone. In a specific example, there may be two calendering rollers in the melting zone, four calendering rollers in the kneading zone, and one calendering roller in the cooling / tempering zone. The various zones may be configured adjacent to one another so that the material always contacts at least one roller during the process.
[0026] Preparation method
[0027] In another example of the present technology, a method for preparing a treated web having a bipolar plate structure, such as a treated graphite-based web having a bipolar plate structure, is described. The method includes providing a system including one or more calendering rollers and one or more treatment rollers, where the system does not include any heating unit disposed between the calendering rollers and the treatment rollers; outputting an untreated web from the calendering rollers; and inputting the untreated web into the treatment rollers to prepare a treated web having at least one bipolar plate structure. In some embodiments, the one or more treatment rollers are positioned adjacent to the one or more calendering rollers. In some embodiments, the one or more treatment rollers include one or more embossing rollers. In some embodiments, the one or more treatment rollers include one or more cutting rollers. In some embodiments, at least one bipolar structure includes at least one embossed bipolar structure. In some embodiments, the one or more bipolar structures include at least one cutting bipolar structure.
[0028] In some embodiments, the one or more embossing rollers include at least one embossing roller with a male embossing feature and at least one embossing roller with a female embossing feature. In some embodiments, the method further includes aligning the male embossing feature with the female embossing feature. In some embodiments, the male embossing feature and the female embossing feature are aligned when the unprocessed web enters between the embossing rollers. In some embodiments, the one or more embossing rollers are configured to output an embossed web having at least one embossed bipolar plate structure.
[0029] In some embodiments, the system further includes one or more cutting rollers, and the method further includes inputting the embossed web into the cutting roller to prepare a cut web. In some embodiments, the system further includes one or more cutting rollers, and the method further includes inputting the untreated web into the cutting roller to prepare a cut web. In some embodiments, the one or more embossing rollers are configured to output a cut web having at least one cut bipolar plate structure. Similarly, one or more combination rollers may be provided before, between, or after the cutting or embossing rollers, such that the output of one roller or group of rollers can be input to the next roller or group of rollers.
[0030] In some embodiments, the one or more cutting rollers include at least one cutting roller or mating roller with a male cutting feature and at least one cutting roller or mating roller with a female cutting feature. In some embodiments, the method further includes aligning the male cutting feature and the female cutting feature. In some embodiments, the male cutting feature and the female cutting feature are aligned when an untreated web enters between the cutting rollers. In some embodiments, the method further includes aligning the male cutting feature and the female cutting feature when an embossed web enters between the cutting rollers or mating rollers.
[0031] In some examples, the temperature of the untreated web as it exits the calendering rollers is substantially equal to the temperature of the untreated web as it enters the treating rollers. In other examples, the method can further include cooling the untreated web after it exits the calendering rollers and before it enters the treating rollers. For example, the untreated web can be cooled to a desired input temperature for the treating rollers. In some embodiments, the treated web can be cooled after treating. In some embodiments, the treated web can be cooled after embossing. In some embodiments, the treated web can be cooled after cutting.
[0032] The method can reduce energy usage, capital expenditures, and operational expenditures compared to systems that have at least one heating unit between the calendering rollers and the treatment rollers. Furthermore, there is no need to wind and unwind untreated material before treatment. The method can also reduce energy consumption compared to systems that do not have a multi-rolling configuration, because the multi-rolling configuration eliminates the need to repeatedly heat the material between rolling steps.
[0033] The resulting treated web having at least one bipolar plate structure may be subjected to further processing such as applying adhesive, winding, cutting, and the like.
[0034] The method may further include one or more additional upstream steps, such as contacting a feedstock between a first roller and a second roller. The feedstock may be in various physical forms, such as powder or flakes. In some examples, the feedstock is graphite powder or graphite flakes. The method may further include melting the feedstock. The method may further include kneading the molten feedstock to create a homogeneous web. The method may further include reducing the homogeneous web to a temperature suitable for embossing. In some examples, the web is supported by at least one roller during the entire preparation method, from initial homogeneous web formation to processing. In these examples, no handling of the web is required between the various preparation steps.
[0035] product
[0036] In another example of the present technology, treated graphite-based webs having at least one bipolar plate structure prepared by one or more of the above-described methods are described. In some embodiments, the treated webs include at least one embossed bipolar plate structure. In some embodiments, the treated graphite-based webs include at least one cut bipolar plate structure. The products produced by the described methods are expected to have superior quality and consistency compared to conventional embossed webs. For example, the products are expected to have fewer defects per unit area and lower stress values.
[0037] Clause 1. A multi-roll method for preparing an embossed web having a bipolar plate structure, comprising: providing a system including one or more calendering rollers and one or more embossing rollers, the system not including any heating unit disposed between the calendering rollers and the embossing rollers; outputting an unembossed web from the calendering rollers; and inputting the unembossed web into the embossing rollers to prepare the embossed web having a bipolar plate structure.
[0038] Clause 2. The method of clause 1, which does not include heating the unembossed web after it has been output from said calendering rollers and before it is input to said embossing rollers.
[0039] Clause 3. The method of clause 1, further comprising cooling the untreated web after it is output from the calendering rollers and before it is input to the treating rollers.
[0040] Clause 4. The method of clause 1, wherein the unembossed web is an unembossed graphite-based web.
[0041] Clause 5. The method of clause 1, wherein the embossed web is an embossed graphite-based web.
[0042] Clause 6. A multi-roll system for preparing an embossed web having a bipolar plate structure, said system comprising one or more calendering rollers and one or more embossing rollers, said system not comprising any heating unit disposed between said calendering rollers and said embossing rollers.
[0043] Clause 7. The system of clause 6, configured such that the output of said calendering roller is the input of said embossing roller.
[0044] Clause 8. The system of clause 6, wherein the output of the calendering rollers is an unembossed web.
[0045] Clause 9. The system of clause 6, wherein the output of the calendering roller is an unembossed graphite-based web.
[0046] Clause 10. The system of clause 6, configured such that the output of the embossing roller is an embossed web having a bipolar plate structure.
[0047] Clause 11. The system of clause 6, configured such that the output of the embossing roller is an embossed graphite-based web having a bipolar plate structure.
[0048] Clause 12. The system of clause 6, including two or more calendering rollers.
[0049] Clause 13. The system of clause 6, comprising seven calendering rollers.
[0050] Clause 14. A system according to clause 6, comprising two, three, four, five, six, seven or eight calendering rollers.
[0051] Clause 15. A system as described in clause 6, including two or more embossing rollers.
[0052] Clause 16. A system as described in clause 6, including two embossing rollers.
[0053] Clause 17. A system according to clause 6, comprising two, three, four, five, six, seven or eight embossing rollers.
[0054] Clause 17. The system of clause 6, wherein the embossed web having a bipolar plate structure is an embossed graphite-based web having a bipolar plate structure.
[0055] Clause 18. An embossed graphite-based web having a bipolar plate structure is prepared by a multi-roll process, the method comprising: providing a system including one or more calendering rollers and one or more embossing rollers, the system not including any heating unit disposed between the calendering rollers and the embossing rollers; outputting an unembossed graphite-based web from the calendering rollers; and inputting the unembossed web into the embossing rollers to prepare the embossed graphite-based web having a bipolar plate structure. [Example]
[0056] Example 1: Assembling the system without heating
[0057] This embodiment is shown in Figures 1 and 2. A set of seven calendering rollers 100 and two treatment rollers 200 can be assembled. The rollers can be configured as two calendering rollers in the melting zone 400, four calendering rollers in the kneading zone 500, and one calendering roller in the cooling / tempering zone 600.
[0058] A pair of processing rollers 200 may be configured directly adjacent to the final seventh calendering roller without a heating unit 300 between them (not shown). The one or more processing rollers 200 may include one or more embossing rollers and / or one or more cutting rollers.
[0059] Example 2: Assembling the system without heating
[0060] This embodiment is shown in Figure 3. A set of seven calendering rollers 100 can be assembled. The calendering rollers can be configured as two calendering rollers in the melting zone 400, four calendering rollers in the kneading zone 500, and one calendering roller in the cooling / tempering zone 600.
[0061] The pair of processing rollers 200 may be constructed separately from the final seventh calendering roller. A heating unit 300 may be positioned before the processing rollers 200. The processing rollers 200 may include one or more embossing rollers and / or one or more cutting rollers.
[0062] Example 3: Use of the system without a heating unit
[0063] This example describes the use of the system of Example 1. A set of calendering rollers can be used to produce an untreated graphite-based web. The web is fed directly from the calendering rollers to a pair of treatment rollers to produce a treated graphite-based web having at least one bipolar plate structure. The treated web is cooled and optionally subjected to further processing.
[0064] Example 4: Use of a system with a heating unit
[0065] This example illustrates the use of the system of Example 2. A set of calendering rollers can be used to produce an untreated graphite-based web. The web is wound, cooled, and transferred to a separate set of treating rollers.
[0066] The untreated web is heated using a heating unit to reach an appropriate desired processing temperature before being passed through a processing roller to produce a treated graphite-based web having at least one bipolar plate structure. The treated web is cooled and optionally subjected to further processing.
[0067] Example 5: Comparison of systems with and without heating
[0068] The system of Example 1 is expected to operate with improved efficiency, consistency, and energy usage compared to the system of Example 2. In particular, the elimination of the heating unit between the calendering rollers and the treatment rollers is expected to significantly reduce energy usage and capital expenditures (CAPEX) / operational expenditures (OPEX). Furthermore, the simpler system is expected to result in less frequent breakages and less need for unplanned maintenance, resulting in less unplanned downtime.
[0069] Example 6: Comparison of Produced Treated Products
[0070] A comparison can be made between the finished treated graphite-based webs having at least one bipolar plate structure produced from Examples 3 and 4. Treated webs produced from the direct system without a heating unit (as described in Examples 1 and 3) are expected to be of better quality than those produced from the indirect system with a heating unit (as described in Examples 2 and 4).
[0071] Example 7: Preparation of treated webs from graphite flakes or powder
[0072] The system shown in Figure 1 is used. Graphite powder or flakes are loaded between the first two calendering rollers, where they are melted in the melting zone. The web then passes through a kneading zone and a cooling / tempering zone to produce an untreated web. The untreated web passes directly through the treating rollers to form a treated graphite-based web with a bipolar plate structure. The web does not leave contact with one or more rollers until it is treated.
[0073] In the foregoing detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, like symbols generally identify like components unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not intended to be limiting. Other embodiments may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings, can be arranged, substituted, combined, separated, and designed in a wide variety of configurations expressly contemplated herein.
[0074] The present disclosure is not limited to the specific embodiments described in this application, but are intended as illustrative of various aspects. As will be apparent to those skilled in the art, many modifications and variations can be made without departing from the spirit and scope thereof. Functionally equivalent methods and apparatuses encompassed within the scope of the present disclosure, in addition to those recited herein, will be apparent to those skilled in the art from the above description. Such modifications and variations are intended to be included within the scope of the appended claims. The present disclosure is limited only by the terms of the appended claims, and the full scope of equivalents to which such claims are entitled. It is understood that the present disclosure is not limited to particular methods, materials, compositions, or systems, which can, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.
[0075] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Nothing in this disclosure should be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used herein, the term "comprising" means "including, but not limited to."
[0076] While various compositions, methods, and devices are described in terms of "comprising" (which should be interpreted as meaning "including, but not limited to") various components or steps, the compositions, methods, and devices may also "consist essentially of" or "consist of" various components and steps, and such terms should be interpreted as defining an essentially closed group of elements.
[0077] With respect to the use of virtually any plural and / or singular term herein, those skilled in the art can convert from plural to singular and / or from singular to plural as appropriate to the context and / or application. For clarity, various singular / plural permutations may be explicitly set forth herein.
[0078] Those skilled in the art will understand that terms used in the specification, in general, and in the claims, in particular (e.g., the body of the claims), are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" as "having at least," the term "includes" as "includes but is not limited to," etc.). Where a specific number of recitations is intended in a proposed claim, such intent will be explicitly stated in the claim, and those skilled in the art will further understand that the absence of such a statement does not mean that such intent is not expressed. For example, as an aid to understanding, the following claims may include the use of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed as implying that the raising of a claim recitation with the indefinite article "a" or "an" limits any particular recitation containing such a raised claim recitation to embodiments containing only one such recitation, even when that same claim includes the introductory phrase "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"); the same applies to the use of definite articles used to raise a claim recitation. Additionally, when a specific number of raised claim recitations is explicitly recited, those skilled in the art will understand that such recitation should be interpreted to mean at least the recited number (e.g., a minimum recitation of "two recitations" without other modifiers means at least two recitations, or more than two recitations).Furthermore, when a rule similar to "at least one of A, B, and C, etc." is used, such interpretation is generally intended in the sense that one of ordinary skill in the art would understand the rule (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems having A only, B only, C only, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). When a rule similar to "at least one of A, B, or C, etc." is used, such an interpretation is generally intended in the sense that one of ordinary skill in the art would understand the rule. (For example, "a system having at least one of A, B, or C" includes, but is not limited to, systems having A only, B only, C only, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.) Furthermore, one of ordinary skill in the art will understand that virtually any separating word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibility of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" is understood to include the possibilities of "A" or "B" or "A and B."
[0079] Additionally, when features or aspects of the disclosure are described in terms of a Markush group, one skilled in the art will understand that the disclosure also describes any individual component or subgroup of components of that Markush group.
[0080] Those skilled in the art will understand that, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein encompass any and all possible subranges and combinations of subranges within that range. Any range described herein can be readily recognized as being fully described, with that same range being divisible into at least two, three, four, five, ten, etc. By way of example and not limitation, each range described herein can be readily divided into a lower third, a middle third, an upper third, etc. Those skilled in the art will also understand that terms such as "up to," "at least," and the like, all refer to ranges that are inclusive of the recited numbers and can subsequently be divided into subranges as described above. Finally, those skilled in the art will understand that ranges include each individual element. Thus, for example, a population having 1 to 3 cells refers to a population having 1, 2, or 3 cells. Similarly, a population having 1 to 5 cells refers to a population having 1, 2, 3, 4, or 5 cells.
[0081] 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 thereof may subsequently occur to those skilled in the art, each of which is intended to be encompassed by the disclosed embodiments.
Claims
1. 1. A multi-roll process for preparing a treated web having a bipolar plate structure, the process comprising: Providing a multi-roll calender system including one or more calendering rollers and one or more treatment rollers, the system not including any heating unit disposed between the calendering rollers and the embossing roller; outputting an unprocessed web from said calendering rollers; inputting the untreated web into the treatment rollers to prepare the treated web having a bipolar plate structure; The method, wherein the one or more processing rollers include one or more cutting rollers, one or more embossing rollers, and / or one or more combining rollers.
2. 10. The method of claim 1, wherein the temperature of the untreated web as it exits the calendering rollers is substantially equal to the temperature of the untreated web as it enters the treating rollers.
3. The method of claim 1 further comprising cooling the untreated web after it is output from the calendering rollers and before it is input to the treating rollers.
4. The method of claim 1 , wherein the untreated web is an untreated graphite-based web.
5. The method of claim 1 , wherein the treated web is a treated graphite-based web.
6. wherein the processing rollers include at least one embossing roller or a combination roller including a male embossing feature and at least one embossing roller or a combination roller including a female embossing feature, and the method comprises: The method of claim 1 , further comprising aligning the male embossing feature and the female embossing feature.
7. wherein the processing rollers include at least one cutting roller or mating roller including a male cutting feature and at least one cutting roller or mating roller including a female cutting feature, and the method comprises: The method of claim 1 , further comprising aligning the male cutting feature and the female cutting feature.
8. The method of claim 1 , wherein the treatment roller is positioned adjacent to the calendering roller.
9. 1. A multi-roll system for preparing a treated web having a bipolar plate structure, said system comprising: one or more calendering rollers and one or more treatment rollers; the system does not include any heating unit disposed between the calendering roller and the treatment roller; The system, wherein the one or more processing rollers include one or more cutting rollers, one or more embossing rollers, and / or one or more combining rollers.
10. The system of claim 9 , wherein an output of the calendering roller is configured to be an input of the processing roller.
11. The system of claim 9 , wherein the output of the calendering rollers is configured to be an unprocessed web.
12. The system of claim 9 , wherein the output of the calendering rollers is configured to be an untreated graphite-based web.
13. 10. The system of claim 9, wherein the output of the processing roller is a processed web having a bipolar plate configuration.
14. 10. The system of claim 9, wherein the output of the treatment roller is a treated graphite-based web having a bipolar plate structure.
15. The system of claim 9 including two or more calendering rollers.
16. 10. The system of claim 9, comprising seven calendering rollers.
17. 10. The system of claim 9, comprising 2, 3, 4, 5, 6, 7, or 8 calendering rollers.
18. The system of claim 9 including two or more processing rollers.
19. 10. The system of claim 9, comprising two processing rollers.
20. 10. The system of claim 9, comprising two, three, four, five, six, seven, or eight processing rollers.
21. 10. The system of claim 9, wherein the treated web having a bipolar plate structure is a treated graphite-based web having a bipolar plate structure.
22. A treated graphite-based web having a bipolar plate structure is prepared by a multi-roll process, the process comprising: Providing a system including one or more calendering rollers and one or more treatment rollers, the system not including any heating unit disposed between the calendering rollers and the treatment rollers; outputting an untreated graphite-based web from said calendering rollers; and inputting the untreated web into the treatment rollers to prepare the treated graphite-based web having a bipolar plate structure; The method, wherein the one or more processing rollers include one or more cutting rollers, one or more embossing rollers, and / or one or more combining rollers.