Fuel Cell Separator Progressive Pressing Burr Management

Solution Overview

Problem

Conventional manufacturing apparatuses for fuel cell separators do not effectively address the generation of burrs during the punching process, which complicates the processing and assembly of separator parts.

Innovation Solution

A progressive pressing method and apparatus that includes a pressing step, a trimming step with the same punching direction as the pressing step, a lifting step, and a conveying step, allowing for efficient discharge of separator parts while managing burrs, and utilizes a hook for easy lifting of the metal plate, ensuring proper alignment and prevention of interference during assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If punching is used to cut loose the separator shaped part from the elongated metal plate, then the separator shaped part can be efficiently separated, but burrs are generated on the punched surfaces

Engineering Contradiction:

Improveefficiency of separationVSAvoidsurface quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The punching direction is predetermined to be the same as the pressing direction, so that burrs are generated in a controlled direction during the trimming step. This preliminary planning of the punching direction allows subsequent deburring operations to be more efficient, as all burrs are generated in the same direction and can be removed more easily.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of trying to completely avoid burr generation during punching, the invention accepts that burrs will be generated but directs them in a controlled manner by aligning the punching direction with the pressing direction. This converts the harmful effect of burr generation into a manageable situation where burrs are consistently oriented and can be efficiently removed in subsequent processing steps.

Inventive Principle:

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

2Productivity

If the separator shaped part is discharged after punching, then production continues, but burrs may interfere with assembly of the separator parts

Engineering Contradiction:

Improvecontinuous productionVSAvoidassembly difficulty

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The punching direction is predetermined to be the same as the pressing direction, so that burrs are generated in a controlled direction during the trimming step. This preliminary planning of the punching direction allows subsequent deburring operations to be more efficient, as all burrs are generated in the same direction and can be removed more easily.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of trying to completely avoid burr generation during punching, the invention accepts that burrs will be generated but directs them in a controlled manner by aligning the punching direction with the pressing direction. This converts the harmful effect of burr generation into a manageable situation where burrs are consistently oriented and can be efficiently removed in subsequent processing steps.

Inventive Principle:

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

3Productivity

If the elongated metal plate is lifted after trimming, then the separator shaped part can be discharged, but the metal plate requires additional handling

Engineering Contradiction:

Improvedischarge capabilityVSAvoidhandling complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The lifting step is combined with the existing pressing apparatus by utilizing the pressing direction for lifting the elongated metal plate. This merging of functions allows the plate to be lifted and discharged without requiring completely separate handling equipment, thereby reducing overall device complexity while maintaining productivity.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11444358B2Manufacturing method for fuel cell separators and manufacturing apparatus for fuel cell separators

Publication Date: 2022.09.13 HONDA MOTOR CO LTD

AI summary

A manufacturing method for fuel cell separators by way of a progressive pressing method which molds a plurality of separator shaped parts in an elongated metal plate, the method having: a pressing step of forming a separator shaped part in an elongated metal plate by way of pressing; a trimming step of cutting loose the separator shaped part from the elongated metal plate by punching an outer peripheral part of the separator shaped part formed in the elongated metal plate in the same pressing direction as the pressing step; a lifting step of lifting up the elongated metal plate from which the separator shaped part was cut loose; and a separator shaped part conveying step of conveying the separator shaped part which was cut loose to a downstream side in the conveying direction, in the midst of the elongated metal plate being lifted up in the lifting step.