Bipolar Plate Roll Forming With Variable Lateral Tension Features
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Solution Overview
Problem
Current methods for manufacturing bipolar plates, particularly roll embossed forming, face challenges such as wrinkling, spring back, and bending due to insufficient lateral tension, limiting mass-scale production and throughput in fuel cell manufacturing.
Innovation Solution
Applying a plurality of lateral tension features of varying heights on both sides of the metal sheet during the forming process, in addition to longitudinal tension, to consistently maintain lateral tension and prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roll embossed forming is used to manufacture bipolar plates, then throughput rate is improved for mass-scale production, but manufacturing defects such as wrinkling, spring back, and bending occur due to insufficient lateral tension
Solution Approach 1:
The lateral tension application is segmented into multiple discrete lateral tension features (first and second lateral tension features) distributed along the metal sheet. Each feature applies localized lateral tension, collectively providing consistent overall lateral tension throughout the forming process, preventing wrinkling and deformation while maintaining high throughput
Solution Approach 2:
The lateral tension features have varying heights (first height and second height) to provide different degrees of lateral tension at different locations along the metal sheet. This localized variation in tension application ensures consistent lateral tension control across the entire forming process, addressing the insufficient lateral tension problem that causes manufacturing defects
2Device complexity
If a single lateral tension feature is used to apply lateral tension during forming, then device complexity is reduced, but lateral tension consistency is insufficient leading to wrinkling and spring back
Solution Approach 1:
Rather than using a single lateral tension feature, the invention segments the lateral tension application into multiple discrete features (first lateral tension feature and second lateral tension feature) positioned at different locations along the metal sheet. This segmentation ensures that lateral tension is applied consistently across the entire forming process, preventing wrinkling and spring back while maintaining manageable device complexity
Data Source
AI summary
A method of manufacturing bipolar plates includes passing a metal sheet through at least one tension roller disposed either upstream or downstream to a BPP forming roll to establish a longitudinal tension on the metal sheet as it passes through the BPP forming roll. A first pair of inner and outer lateral tension features are formed along a first side of the metal sheet and a second pair of inner and outer later tension features are formed along a second side of the metal sheet for use in establishing a lateral tension on the metal sheet as it passes through the BPP forming roll. The inner and outer lateral tension features in each of the first and second pairs have varying or different heights to advantageously provide a more consistent application of the lateral tension to the metal sheet.