Fuel Cell Metal Separator Trapezoidal Irregularities
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Solution Overview
Problem
Existing metal separators for fuel cells with poor processing characteristics tend to crack during the press molding process, limiting the formation of complex irregularities and reducing the accuracy and effectiveness of the separator, especially when using materials with low ductility and corrosion resistance.
Innovation Solution
A metal separator formed with a metal plate featuring trapezoidal irregularities, where the wall thickness of flat portions is adjusted to 90% or less through compressive stress, allowing for the formation of slope and upper flat portions without cracking, using materials like Ti clad aluminum or stainless steel with low ductility, and employing a fabrication method that includes compression and molding press processes to manage stress and prevent tensile stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If press molding is used to form metal separator with complex irregularities, then productivity is improved and cost is reduced, but materials with low ductility crack during the process
Solution Approach 1:
The method applies preliminary compressive stress to the metal plate before forming the irregularities. This preliminary action pre-strains the material in compression, which prevents tensile stress from causing cracks during the subsequent forming process, enabling low-ductility materials to be successfully molded.
Solution Approach 2:
The invention changes the stress state parameter from tensile to compressive during the forming process. By applying compressive stress instead of tensile stress, the material behavior is altered to prevent crack formation, allowing materials with low ductility to be formed into complex shapes without failure.
2Manufacturing precision
If conventional press molding is used without compressive stress, then the process is simple, but complex irregularities cannot be formed with high accuracy
Solution Approach 1:
The compressive stress application is performed as a preliminary step before the actual forming operation. This preliminary action prepares the material by inducing compressive strain, which enables the subsequent formation of complex irregularities with high precision without causing cracks, thus improving manufacturing precision.
3Duration of action of stationary object
If materials with high corrosion resistance and low ductility are used, then separator lifespan is improved, but processing characteristic deteriorates
Solution Approach 1:
The invention changes the stress parameter from tensile to compressive during manufacturing. This parameter change allows materials with high corrosion resistance but low ductility to be processed successfully, as compressive stress does not cause crack propagation in these materials, thereby improving ease of manufacture while maintaining material benefits.
Solution Approach 2:
By applying compressive stress as a preliminary action before forming, the material is pre-conditioned to resist crack formation. This enables the use of high-performance materials with low ductility, improving both separator lifespan and processability simultaneously.
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
Enables the formation of complex irregularities with high accuracy and reduces the likelihood of cracking, even with materials having low ductility, resulting in improved separator performance with enhanced corrosion resistance and longer lifespan.
Implementation Method 1
where the wall thickness of flat portions is formed uniformly and thinly to 90% or less of that of the metal plate to be formed in order to obtain trapezoidal irregularities by forming flat portions which contact upper and lower cells
Implementation Method 2
the metal plate is formed like trapezoidal irregularities to separate channels for a fuel gas from ones for an oxidant gas
Data Source
AI summary
A metal separator for fuel cells formed with a metal plate and provided between cells accumulated, in which the metal plate is formed like trapezoidal irregularities to separate channels for a fuel gas from ones for an oxidant gas. Slope portions are formed after forming uniformly and thinly wall thickness of both upper and lower flat portions or either of the upper or the lower flat portion to 90% or less of that of the metal plate to be formed to obtain trapezoidal irregularities by forming flat portions which contact upper and lower cells and slope portions which interconnect the upper and the lower flat portions.