Method of producing a collecting channel for an electrolysis cell, collecting channel and electrolysis cell

Abstract

A method of producing a collecting channel for an electrolysis cell, a collecting channel, and an electrolysis cell are provided. The method comprises a step of providing a metal sheet (S1) and a step of shaping (S2) the metal sheet into a channel profile (1) that extends longitudinally in a first direction and has a hollow cross section (11) along a second direction perpendicular to the first direction, wherein the step of shaping the metal sheet includes roll-forming the sheet into the hollow cross section.

Description

[0001] 01.09.2025

[0002] 230764P10WO

[0003] Method of producing a collecting channel for an electrolysis cell, collecting channel and electrolysis cell

[0004] Description

[0005] The present invention relates to a method of producing a component for electrolysis cell and the component, particularly to a method of producing a collecting channel, as well as to the collecting channel and an electrolysis cell with the collecting channel.

[0006] Currently, single-element electrolysis cells are divided into cathode and anode half shells. A collecting channel is an essential component of the half shells. The functionalities of collecting channels include gas and / or liquid collection, calming the gas-liquid-phase of the media to promote the removal of product gases, and safety features to avoid equipment failures and leaks.

[0007] The conventional production method of collecting channels involves complex processes that limit scalability and cost efficiency. Increasing the production quantities necessitates duplicating existing production lines, such as laser cutting, bending, followed by laser or arc welding, which prevents cost degression and scaling effects. In addition, merely limited cross-sectional geometries may be realised.

[0008] Furthermore, the conventional production method of collecting channels separates components piece by piece at the beginning of the production process, which involves manual handling such as quality control and results in a discontinuous process. With increasing annual quantities, this discontinuous process hinders the production efficiency.

[0009] In addition, there is a need to maintain in use a gap between the collecting channel and the opposing wall in an electrolysis cell, so that the gas and / or fluid is collected efficiently. The conventional collection channel involves complex processes and additional components to maintain the gap, e.g. forming an interspace and installing a separate spacer therein.

[0010] It is an object of the present invention to provide a method of producing a collecting channel for an electrolysis cell, which may allow to reduce production costs. The inventive method should also allow for scaling effects and improve production efficiency with increased production quantities. Different cross- sectional geometries may be realised through this production method as well. In addition, the present invention aims at providing a collection channel, which can maintain the gap between the collecting channel and the opposing wall in an electrolysis cell without involving complex processes or additional components. Further, the invention should provide an electrolysis cell.

[0011] According to the invention, the object with regard to the production method is achieved by the subject matter of claim 1. With regard to the collecting channel, the above-mentioned object is achieved by the subject matter of claim 12 and with regard to the electrolysis cell by claim 13.

[0012] In particular, the method of producing a collecting channel for an electrolysis cell according to the present invention comprises the steps of providing a metal sheet and shaping the metal sheet into a channel profile that extends longitudinally in a first direction and has a hollow cross section along a second direction perpendicular to the first direction. According to the invention the step of shaping the metal sheet includes roll forming the sheet into the hollow cross section.

[0013] Roll forming is a type of rolling involving continuous bending of a metal sheet into a desired cross section using multiple contoured rolls, in particular multiple pairs of contoured rolls. The invention is not limited to the use of specific rolls. The rolls and / or the arrangement of the rolls can be selected so as to obtain the desired hollow cross section of the collecting channel. The cross section may be any polygons, which may include one or more curves. Preferably, the cross section is trapezoidal.

[0014] In other words, the walls of the collecting channel which define and limit the hollow cross section are bent by roll forming to obtain the desired channel profile. The inventive method, in particular the step of shaping the metal sheet including roll forming the sheet into the hollow cross section can be adapted to form a great variety of different cross sections, e.g. a cross section having a polygonal contour, preferably a trapezoidal cross section.

[0015] To this end, the contoured rolls used for the step of roll forming can be accordingly selected and / or arranged so as to generate the desired contour of the cross section.

[0016] Roll forming has the advantage that it is suitable for series production with high production quantities, which makes the inventive method a technologically and economically viable series production method. In addition, roll forming allows for the addition of detailed features like grooves, ridges, and embossments within the profile, so that almost all possible cross-sectional geometries can be realized. Furthermore, the separation of components may be carried out as late as possible due to the continuous process, so that post-processing after separation is reduced to a minimum and production efficiency is improved.

[0017] A collecting channel according to present invention comprising a channel profile that extends longitudinally in a first direction and has a hollow cross section along a second direction perpendicular to the first direction, wherein the channel profile includes a protrusion that extends outwardly on the outside surface of the channel profile, preferably, wherein the protrusion is so sized as to maintain in use a gap with respect to an opposing wall in the electrolysis cell, preferably, wherein the protrusion extends in the first direction.

[0018] The channel profile includes a protrusion, which is not a separate element but a monolithic part of the channel. The monolithic part is more stable than the installed components. The external parts and their installation may also be avoided.

[0019] The opposing wall defines a volumetric space for a cathode or anode chamber of the half shell and provides a mounting surface for the collecting channel or the like. The collecting channel is typically located at the top of the half shell.

[0020] It is clarified that the collecting channel is disclosed and claimed as a product as such, i.e. as a component for an electrolysis cell. Said component can be de- livered by a supplier and assembled by the manufacturer of the electrolysis cell or the component can be produced and assembled by the same manufacturer.

[0021] It is clarified, that the inventive method is not restricted to a completely continuous process. The roll forming of the inventive method, however, allows to implement a process that is to a large extend continuous which increases the efficiency of production and allows to establish parallel production lines for the components of the collecting channel.

[0022] Moreover, an electrolysis cell with an inventive collecting channel is disclosed and claimed.

[0023] Advantageous embodiments of the invention are specified in the dependent claims.

[0024] In a preferred embodiment, after the step of roll forming the sheet into the hollow cross section, the method may further include bending the metal sheet so that both width ends of the metal sheet come to face each other, and joining both the facing ends of the bent sheet along the longitudinal direction of the channel profile. This embodiment may also include separating the joined channel profile to form the collecting channel with a predetermined length. The advantage is that the number of steps carried out during the continuous process is increased prior to separating the joined channel profile into single collecting channels, which further improves the production efficiency.

[0025] Further steps can be carried out in the continuous phase of the process prior to the separation step.

[0026] In the above embodiment, one or more holes or openings may be provided in the metal sheet. By removing gas bubbles promptly, the holes prevent blockages or slowdowns in the electrolyte flow.

[0027] In addition or alternatively a collar for a component, in particular a nozzle, may be provided, which may facilitate the installation of the corresponding component with an enhanced quality for the joint. The collar may be provided preferably by stamping, so that the collar can be formed efficiently and accurately. This embodiment does not restrict the process sequence nor does it exclude further steps that can be carried out in the continuous phase of the process prior to the separation step.

[0028] In the above embodiment, providing the one or more holes on the metal sheet is preferably performed by punching or cutting, so that one or more holes can be formed efficiently and accurately.

[0029] In a further preferred embodiment, the method may include a step of providing one or more protrusions on or in the channel profile. This step is preferably carried out by punching or stamping, so that an efficient and accurate process is ensured.

[0030] The protrusions are typically produced by locally forming the wall of the collecting channel. Preferably, the one or more protrusions extend outwardly, i.e. the one or more protrusions are part of the outer contour or outer surface of the channel profile.

[0031] The formation of the protrusions can be carried out prior or during the step of roll forming. By applying a tool like a punch or stamp prior to roll forming i.e. to the metal sheet it is possible to form the protrusions in a plane, i.e. into the metal sheet by using a conventional punching or stamping process. The metal sheet with the protrusions is then roll formed to produce the channel profile. By applying an accordingly contoured roll, it is possible to form the protrusions during roll forming. Theoretically, it is also possible to combine both steps, however, this is more complicated from a production point of view.

[0032] In another preferred embodiment, the step of joining both the facing ends in the bent sheet may comprise a welding step, in particular laser welding, arc welding and / or resistance welding. Thereby a high joint strength and a good resistance to environmental conditions of the collecting channels is achieved.

[0033] In a further preferred embodiment, the step of joining both the facing ends in the bent sheet comprises a mechanical joining step, in particular clinching, folding, flanging and / or beading. The mechanical joining step may be performed alone or in combination with the welding step in the above embodiment. This allows for a good flexibility to join the facing ends and, if desired, further enhances the joint strength and resistance to environmental conditions. In another preferred embodiment, the method may comprise steps of attaching a component on a periphery of the channel profile to output liquid and / or gas after the roll forming and / or closing both longitudinal ends of the channel profile after the roll forming, preferably by side frames. The effect is that merely two further steps need to be carried out after the continuous part of the method, which further improves the efficiency of production.

[0034] It is clarified, that the inventive method is not restricted to a completely continuous process. The roll forming of the inventive method, however, allows to implement a process that is to a large extent continuous which increases the efficiency of production and allows to establish parallel production lines for the components of the collecting channel.

[0035] In the embodiment above, the component and / or the side frames may be prepared before or during the roll forming of the sheet, in respective production lines. The effect is that the efficiency of production can be further improved, in particular if the component and / or the side frames are prepared during the roll forming of the sheet in parallel to the channel profile.

[0036] In another preferred embodiment, the metal sheet to produce the channel profile may be made of nickel or nickel alloy. This leads to a good material resistance of the collecting channel against corrosion.

[0037] In a further preferred embodiment, the metal sheet to produce the channel profile may have a thickness in a range of 0.3 mm to 0.7mm, preferably in a range of 0.4 mm to 0.6 mm, and more preferably, the metal sheet has a thickness of about 0.5 mm. The corresponding effect is that the manufacturing process of collecting channel may be carried out smoothly.

[0038] The invention is explained in more detail below with reference to the accompanying schematic drawings. The embodiments shown are examples of how the production method according to the invention can be carried out.

[0039] FIG. 1 is a flow chart showing an overview of manufacturing collecting channels according to a preferred embodiment of the invention. FIG. 2 is a flow chart showing a continuous process of producing a channel profile according to a preferred embodiment of the invention.

[0040] FIG. 3 illustrates the structure of a channel profile according to a preferred embodiment of the invention.

[0041] FIG. 4 illustrates a collecting channel with closed longitudinal ends and an attached component according to a preferred embodiment of the invention.

[0042] FIG. 5 illustrates the cross section of a collecting channel in use in an electrolysis cell according to a preferred embodiment of the invention.

[0043] FIG. 6 illustrates an example of a roll set, which may be generally used for roll forming.

[0044] FIG. 7 illustrates another example of a roll set, which may be generally used in roll forming.

[0045] In the following description, the same reference numbers are used for identical or equivalent parts or steps.

[0046] FIG. 1 is a flow chart showing an overview of the production or manufacturing of the collecting channels according to an embodiment of the invention. In step SI, a metal sheet is provided to be processed. The metal sheet, for example, may be provided by uncoiling a metal coil. This embodiment does not restrict any other means of providing a suitable metal sheet to be processed. In step S2, the metal sheet is manufactured into a channel profile with a predetermined hollow cross section and length. Step 2 will be explained below in more detail. In Steps S3 and S4, components to output liquid or gas and to close both longitudinal ends of the channel profile are provided. In step S5, the provided components are attached to the channel profile.

[0047] Merely step S5 needs to be performed after continuous part of the process, which improves the efficiency of production. Furthermore, the component and / or the side frames may be prepared before or during the roll forming of the sheet, in respective production lines, so that the efficiency of production can be further improved. Alternatively, said components can be supplied by an external supplier. The term "providing a component" encompasses both alternatives, external supply and preparation in the sense of internal production in parallel production lines.

[0048] FIG. 2 is a flow chart showing the continuous process of producing channel profiles according to the preferred embodiment of the invention. Step S2 in FIG.

[0049] 1 comprises steps S21-S24 in FIG. 2. Further steps can be included.

[0050] In step S21, geometries are formed on or into the metal sheet. The geometries may be one or more holes or openings, which prevent blockages or slow-downs in the electrolyte flow by removing gas bubbles promptly. One or more holes may be formed in the metal sheet by punching or cutting. The geometries may be a collar for a component, in particular a nozzle, which may facilitate the installation of the corresponding component. The collar may be preferably formed by stamping. The geometries may be one or more protrusions to maintain in use a gap between the collecting channel and the opposing wall in an electrolysis cell. One or more protrusions may be formed by punching or stamping.

[0051] It is also possible to form geometries in step S22 e.g. using suitable contoured rolls.

[0052] The geometries may be one of the above mentioned geometries or any combination of them. The geometries may be formed efficiently and accurately by using the corresponding processes.

[0053] In step S22, the metal sheet is formed to have the hollow cross section by roll forming thereby continuously bending the metal sheet into the desired cross section using multiple pairs of contoured rolls to achieve the desired hollow cross section. A production line with 4-10 sets of rolls may be provided to balance efficiency, quality, and cost-effectiveness.

[0054] As examples, roll sets that may be generally used for roll forming are shown in FIG. 6 and FIG. 7. A roll set includes a first roll 5 and a second roll 6. The first roll 5 comprises a first forming portion 51 and a first rotation axis 52. The second roll 6 comprises a second forming portion 61 and a second rotation axis 62. The first forming portion 51 and the second forming portion 61 may have shapes corresponding to each other. During roll forming, the metal sheet passes through the sets of rolls mounted on consecutive stands. While the first roll 5 and the second roll 6 rotate are rotating along the first rotation axis 52 and the second rotation axis 62 respectively, the desired cross section is formed by the first forming portion 51 and the second forming portion 61. When selecting roll sets, the predetermined hollow cross section of the channel profile has to be taken account. The roll sets to achieve the present invention are not restricted by FIG.

[0055] 6 and FIG. 7.

[0056] In step S23, the roll-formed channel profile is closed along the longitudinal direction, which is achieved by bending the metal sheet so that both width ends of the metal sheet come to face each other. Then both facing ends of the bent sheet are joined along the first direction of the channel profile. Joining both the facing ends of the bent sheet may comprise a welding step, in particular laser welding, arc welding and / or resistance welding The firmly-bonded or material-locked joint achieved by welding leads both to a high joint strength and tightness as well as a good resistance to environmental conditions of the collecting channel.

[0057] Joining both the facing ends in the bent sheet may also comprise a mechanical joining step, in particular clinching, folding, flanging and / or beading. The mechanical joining step may be performed alone or in combination with the welding step, so that it is flexible to select a process to join the facing ends, which is best suitable under cost and constructional aspects.

[0058] In step S24, the channel profile having the hollow cross section and being closed along the longitudinal direction is separated, e.g. cut, to a predetermined length. The single channel profile is thus available for further processing. The continuous part of the process including the step of roll forming is terminated.

[0059] The process sequence of the invention is not restricted by this embodiment. For example, one or more holes or the collar for a component may be formed between steps S22 and S23 or between Steps S23 and S24.

[0060] FIG. 3 illustrates the structure of a channel profile 1 according to a preferred embodiment of the invention which is produced by the method exemplified in Fig. 1, 2. The channel profile 1 comprises a hollow cross section 11 formed by roll forming, holes 12, which prevent blockages or slow-downs in the electrolyte flow by removing gas bubbles promptly, and protrusions 13 to maintain in use a gap between the collecting channel and the opposing wall 4 in an electrolysis cell.

[0061] The cross section 11 is trapezoidal, of which two sides are parallel and the other two sides are slanted. On one slanted side of collecting channel, which is the top side in use, holes 12 are arranged in the longitudinal direction of the channel and spaced apart from each other. On the same side, where the holes 12 are arranged, protrusions 13 are distributed in the longitudinal direction of the channel and spaced apart from each other.

[0062] The specific hollow cross section and the shape of protrusions are not restricted by FIG. 3. The collecting channel may have any other hollow cross section being formed by roll forming, as long as the functionalities of a collecting channel can be achieved. The protrusions may have other shapes. Preferably, the protrusions 13 are a monolithic part of the channel 1. In use, i.e. after assembly of the electrolysis cell, the protrusions 13 allow for a gap between the collecting channel 1 and the opposing wall in an electrolysis cell.

[0063] FIG. 4 illustrates a collecting channel 1 produced according to the method of fig. 1, 2 with closed longitudinal ends and an attached component. In this embodiment, a component 3, preferably a nozzle, is attached on a periphery of the channel profile 1 to output liquid and / or gas. Both longitudinal ends of the channel profile 1 are closed by side frames 2. The side frames 2 function as covers that close both axial ends of the collecting channel 1. The nozzle 3 and side frames 2 may be attached to the collecting channel by welding.

[0064] FIG. 5 illustrates the cross section of a collecting channel 1 in use in an electrolysis cell according to a preferred embodiment of the invention. Protrusion 13 maintains a gap between the channel profile 1 and opposing wall 4. The gap keeps more gas and / or liquid therein, which drops into collection channel due to gravity. After attaching a web structure (not shown) positioned below the collecting channel to the half shell by laser welding, the collecting channel may be welded to the web structure, preferably using TIG track welding.

[0065] The protrusion 13 is not a separate element but a monolithic part of the channel formed into the wall of the channel profile. The monolithic part is more robust and more easily produced than separate components attached to the channel profile. The specific shape of protrusions is not restricted by FIG. 5.

[0066] The metal sheet to produce the channel profile may be made of nickel or nickel alloy which gives a good resistance against corrosion.

[0067] The metal sheet to produce the channel profile may have a thickness in a range of 0.3 mm to 0.7mm, preferably in a range of 0.4 mm to 0.6 mm, and more preferably, the metal sheet has a thickness of about 0.5 mm.

[0068] The features of the above embodiments are disclosed as isolated feature as well as combined features and are claimed as far as novel.

[0069] Reference numerals

[0070] 1 Channel profile

[0071] 11 Hollow cross section

[0072] 12 Holes in the channel profile

[0073] 13 Protrusions on the outside surface of the channel profile

[0074] 2 Side frames

[0075] 3 Component to output liquid and / or gas

[0076] 4 Opposing wall

[0077] 5 First roll

[0078] 51 First forming portion

[0079] 52 First rotation axis

[0080] 6 Second roll 61 Second forming portion

[0081] 62 Second rotation axis

Claims

Claims1. A method of producing a collecting channel for an electrolysis cell, comprising steps of:- providing a metal sheet (SI); and- shaping (S2) the metal sheet into a channel profile (1) that extends longitudinally in a first direction and has a hollow cross section (11) along a second direction perpendicular to the first direction, wherein the step of shaping the metal sheet includes roll forming the sheet into the hollow cross section.

2. The method according claim 1, wherein the step of shaping the metal sheet includes bending the metal sheet so that both width ends of the metal sheet come to face each other, the method further comprising steps of:- joining (S23) both the facing ends of the bent sheet along the first direction of the channel profile, after the step of roll forming the sheet into the hollow cross section; and- separating (S24) the joined channel profile to form the collecting channel with a predetermined length.

3. The method according to claim 2, further comprising steps of:- providing (S21) one or more holes (12) in the metal sheet and / or- providing (S21) a collar for a component, in particular a nozzle (3), on the channel profile, preferably by stamping.

4. The method according to claim 3, wherein providing the one or more holes (12) on the metal sheet is performed by punching or cutting.

5. The method according to any one of claims 2 to 4, further comprising a step of forming one or more protrusions (13) on or in the channel profile preferably by punching or stamping.

6. The method according to any one of claims 2 to 5, wherein the step of joining (S23) both the facing ends in the bent sheet comprises a welding step, in particular laser welding, arc welding and / or resistance welding.

7. The method according to any one of claims 2 to 6, wherein the step of joining (S23) both the facing ends in the bent sheet comprises a mechanical joining step, in particular clinching, folding, flanging and / or beading.

8. The method according to any one of claims 1 to 7, further comprising steps of:- attaching (S5) a component (3) on a periphery of the channel profile to output liquid and / or gas after the roll forming and / or- closing (S5) both longitudinal ends of the channel profile after the roll forming, preferably by side frames (2).

9. The method according to claim 8, wherein the component and / or the side frames are prepared (S3, S4) before or during the roll forming of the sheet, in respective production lines.

10. The method according to any one of claims 1 to 9, wherein the metal sheet is made of nickel or nickel alloy.

11. The method according to any one of claims 1 to 10, wherein the metal sheet has a thickness in a range of 0.3 mm to 0.7mm, preferably in a range of 0.4 mm to 0.6 mm, and more preferably the metal sheet has a thickness of about 0.5 mm.

12. A collecting channel for an electrolysis cell, comprising: a channel profile (1) that extends longitudinally in a first direction and has a hollow cross section (11) along a second direction perpendicular to the first direction, wherein the channel profile includes a protrusion (13) that extends outwardly on the outside surface of the channel profile, preferably, wherein the protrusion is so sized as to maintain in use a gap with respect to an opposing wall (4) in the electrolysis cell, preferably, wherein the protrusion extends in the first direction.

13. Electrolysis cell with a collecting channel according to claim 12.

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