Bipolar Plate Positioning Openings for Precise Stack Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bipolar plates in electrochemical systems face challenges in achieving precise alignment and positioning due to inaccuracies in manufacturing tolerances, leading to potential thermal damage, leaks, and impaired media supply during welding and stacking processes.
Innovation Solution
A bipolar plate design featuring positioning openings with crimpings that allow for accurate alignment using a single forming tool, eliminating the need for separate positioning systems and reducing manufacturing tolerances, enabling precise positioning and alignment of individual plates and subsequent bipolar plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple tools are used for machining individual plates (embossing tool and punching tool), then functional structures can be created, but manufacturing precision deteriorates due to alignment inaccuracies between tools
Solution Approach 1:
The patent combines the embossing tool and punching tool into a single integrated tool that performs both functions simultaneously. The tool includes both an embossing element for creating channel structures and a punching element for creating positioning openings and through-openings, eliminating alignment errors between separate tools and ensuring precise relative positioning of all features.
Solution Approach 2:
The machining tool is designed with multi-functionality, capable of performing both embossing and punching operations in a single step. This universal tool creates positioning openings, through-openings, and channel structures simultaneously, ensuring all features are precisely aligned according to the ideal relative alignment defined in the tool design.
2Productivity
If positioning holes are formed simultaneously with other through-openings and cutting, then productivity increases, but positioning accuracy deteriorates leading to alignment errors
Solution Approach 1:
The patent merges the formation of positioning openings with the creation of other through-openings and cutting operations into a single simultaneous machining step. The integrated tool creates all openings and channels at once, maintaining precise alignment while maximizing production efficiency.
3Reliability
If tight dimensional tolerances are required for functional and safety, then system reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent reduces manufacturing process complexity by combining multiple machining operations into a single integrated tool that creates positioning openings, through-openings, and channel structures simultaneously. This eliminates the need for multiple separate tools and alignment steps, making it easier to maintain tight dimensional tolerances for functional and safety requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the accuracy and reproducibility of bipolar plate alignment, reducing the risk of thermal damage and leaks while optimizing media supply and waste heat transmission, thereby improving the overall performance and reliability of electrochemical systems.
Implementation Method 1
The first crimping forms at least one first contact area for a first positioning pin and the second crimping forms at least one second contact area for the first positioning pin
Implementation Method 2
an embossing tool for deforming regions of the individual plate
Implementation Method 3
a punching tool for creating through-openings in the individual plate
Implementation Method 4
two individual metal plates which are joined together, typically by welding
Data Source
AI summary
Systems and methods for one or more bipolar plate and a stack for an electrochemical system. The bipolar plate comprising a first individual plate and a second individual plate. The first individual plate has at least one first positioning opening with a first crimping. The second individual plate has at least one second positioning opening with a second crimping. The first positioning opening and the second positioning opening of the individual plates arranged in alignment with each other. The first crimping forms at least one first contact area for a first positioning pin and the second crimping forms at least one second contact area for the first positioning pin.