Flow Field Fuel-Cell Plate Line With Continuous Strip Processing
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Solution Overview
Problem
Conventional production lines for flow field fuel-cell plates face productivity and lead time issues due to multiple storage, loading, and unloading steps, leading to increased reject rates and costs, even with automated systems.
Innovation Solution
A production line comprising a conveying device, stamping device, cleaning device, coating device, welding device, and injection-molding machine, where metal strips are continuously conveyed and processed to form flow field fuel-cell plates with alternating anode and cathode formations, utilizing ultrasound cleaning, physical vapor deposition coating, laser welding, and parallel overmolding to enhance efficiency and reduce rejects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If multiple storage, loading, and unloading stations are used for each production step, then automated production is achieved, but productivity decreases and lead time increases
Solution Approach 1:
The patent merges multiple discrete production stations (storage, loading, unloading) into a single integrated continuous production line where metal strips pass through stamping, cleaning, coating, welding, and injection molding in one continuous flow, eliminating the need for separate stations and intermediate handling
Solution Approach 2:
The production line implements continuous processing where metal strips are constantly moved through all production stages without interruption, stopping only when a complete fuel cell plate is formed, thereby maintaining continuous useful action throughout the entire production process
2Extent of automation
If multiple storage, loading, and unloading steps are implemented, then automated production is achieved, but reject rate increases
Solution Approach 1:
The patent combines multiple handling operations into a single continuous process, eliminating intermediate transfer points where components could be damaged or contaminated, thereby reducing the reject rate while maintaining automation
Solution Approach 2:
By maintaining continuous processing without interruption or intermediate storage, the system minimizes the opportunities for defects to occur during handling and transfer operations, thereby improving product reliability and reducing rejects
3Extent of automation
If multiple storage, loading, and unloading operations are used, then automated production is achieved, but production cost increases
Solution Approach 1:
The patent consolidates multiple separate production stations into one integrated continuous production line, reducing the total number of machines, operators, and support systems needed, thereby lowering capital investment and operational costs while maintaining automation
Solution Approach 2:
The continuous production process eliminates the need for multiple storage areas, intermediate handling equipment, and repeated loading/unloading operations, reducing infrastructure costs and operational expenses associated with automated production
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 approach increases productivity and lead time while reducing production rejects and costs by maintaining continuous processing and automating key steps, ensuring efficient production of flow field fuel-cell plates with improved quality control.
Implementation Method 1
the cleaning device is designed to generate an ultrasound for cleaning when cleaning the metal plates
Implementation Method 2
coating of the metal plates is carried out by means of the coating device... coating of the metal plates with the coating device is performed by plasma spraying, atmospheric chemical vapor deposition, vacuum chemical vapor deposition
Data Source
AI summary
The invention relates to a production line (1) for producing a flow field fuel-cell plate (100) and to a method for producing a flow field fuel-cell plate (100) from a continuous or discontinuous metal strip (10) by means of the production line (1), which comprises a conveying device (2), a stamping device (3), a cleaning device (4), a coating device (5), a welding device (6), and an injection-molding machine (7). The production method initially comprises stamping the metal strip (10) by means of the stamping device (3) and thus forming metal plates (11) on the metal strip (10), subsequently cleaning the metal plates (11) by means of the cleaning device (4), thereupon coating the metal plates (11) by means of the coating device (5), thereafter welding the metal plates (11) by means of the welding device (6), two metal plates (11) being joined to each other such that they each form a flow field fuel-cell plate (100) having a cathodic side and an anodic side; and finally overmolding each flow field fuel-cell plate (100) by means of the injection-molding machine (7), wherein the conveying device (2) is designed to convey the metal strip (10) within the production line (1), and wherein the metal strip (10), the metal plates (11) and the flow field fuel-cell plates (100) are disposed on the conveying device (2) during the entire production method and are conveyed, in particular continuously, by the conveying device (2).