Powder Metallurgy Molded Part with Inclined Ridge Elevations

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Solution Overview

Problem

The production of interconnectors and end plates for fuel cell stacks using powder metallurgy faces challenges in achieving high material density and reliable gas separation due to the limitations of trapezoidal cross sections, which are difficult to manufacture and require costly multi-stage pressing processes, especially with brittle alloys like those containing high chromium.

Innovation Solution

The use of powder metallurgical molded parts with multiple knob-shaped or ridge-shaped elevations featuring different angles of inclination on the same side, allowing for a combination of geometries that facilitate high material density, homogeneous structure, and cost-effective single-stage pressing, while improving demolding and gas separation by adapting the pressing tool geometry.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If trapezoidal cross sections with rectilinear inclined flanks are used, then manufacturing is simplified compared to rectangular cross sections, but material density and homogeneity deteriorate

Engineering Contradiction:

Improveease of manufactureVSAvoidmaterial density

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The invention changes the geometric parameters of the elevation cross-section by introducing specific angle ranges (30°-60° for first inclined flanks, 60°-80° for second inclined flanks) and rounded corner portions, transforming the conventional trapezoidal shape into a modified geometry that achieves both manufacturability and high material density with small density gradients

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies different inclination angles to different regions of the same elevation - steeper angles (60°-80°) in certain areas and gentler angles (30°-60°) in other areas, creating local geometric variations that optimize both pressing behavior and final density distribution throughout the molded part

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If conventional trapezoidal elevations are used, then production cost is reduced compared to rectangular elevations, but gas separation reliability deteriorates

Engineering Contradiction:

Improveproduction costVSAvoidgas separation

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

By modifying the elevation geometry with specific angle ranges and rounded corners, the invention creates a cross-section shape that enables reliable gas separation through improved material density and homogeneity, while remaining compatible with powder metallurgy manufacturing processes to maintain cost-effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention converts the potential harm of complex geometry (which would increase manufacturing difficulty) into a benefit by showing that carefully controlled geometric modifications actually simplify the pressing process and improve density uniformity, thereby enhancing gas separation reliability without sacrificing manufacturability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If single-stage pressing is used, then productivity is improved, but achieving high material density with brittle alloys deteriorates

Engineering Contradiction:

ImproveproductivityVSAvoidmaterial density

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The invention changes the geometry parameters of the elevation cross-section to angles and rounded portions that are particularly suitable for single-stage pressing of brittle alloys, enabling the material to flow and densify uniformly in one pressing operation without cracking or excessive density gradients

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention incorporates rounded corner portions and optimized angle configurations in the elevation design that prepare the powder compact for uniform densification during pressing, preventing stress concentrations that would cause defects in brittle alloys during single-stage pressing

Inventive Principle:

Principle #10Preliminary action

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 results in a high-quality molded part with reliable gas separation and reduced defective parts, enabling cost-effective production of interconnectors and end plates for fuel cell stacks with improved mechanical integrity and long-term performance.

Implementation Method 1

pulverulent starting materials are pressed as far as possible into the final shape

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

then sintered

Methodology Applied

Scientific EffectSintering: Sintering

Data Source

PatentUS9472816B2Molded part

Publication Date: 2016.10.18 PLANSEE SE

AI summary

A powder metallurgical molded part includes a disk or plate-like main body and a row of knob-shaped and/or ridge-shaped elevations in a row direction having a height perpendicular to a main plane of the main body and a cross section with side flanks leading from an outer end contour in height direction of the elevation via rounded corner portions into curved portions with a curve radius. The curve radius merges into the surface contour of the main body and a rectilinear flank portion or tangent of the side flank lying at the point where the rounded corner portion merges into the curved portion is disposed at an angle of inclination to the main plane. At least two different angles of inclination are on the same side of the main body and the at least two different angles of inclination represent at least first and second geometries.