Separator Plate Weld Joint Layout to Prevent End-Crater Cracks
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Solution Overview
Problem
Existing separator plates for electrochemical systems face challenges in maintaining stability and durability due to weak points in the welded joints, particularly at the ends, which can lead to tears, leaks, and reduced service life under operating pressures.
Innovation Solution
The proposed separator plate design features a welded joint with an end crater spaced from the ends of the joint, and the joint can be designed without forming an end crater in the end regions. This configuration reduces stress concentrations and potential cracks, enhancing the joint's durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional welding methods are used to connect individual plates, then the separator plate can be manufactured with standard processes, but the welded joints develop end craters and star-shaped cracks that lead to leakage and reduced durability
Solution Approach 1:
The patent changes the welding parameters by controlling the laser welding process to prevent end crater formation. This is achieved by optimizing welding speed, power, and other parameters to ensure the weld pool solidifies properly without creating vulnerable end craters that lead to star-shaped cracks and leakage.
Solution Approach 2:
The patent converts the potentially harmful end crater effect into a beneficial smooth transition zone. By carefully controlling the welding process, the end region of the weld seam becomes a smooth, crack-free area that enhances joint durability rather than creating a weak point for star-shaped cracks and leakage.
2Manufacturing precision
If high positioning accuracy is required for narrow channel widths and intersecting channels, then the channel structure can be precisely formed, but the production complexity and time increase significantly
Solution Approach 1:
The patent applies preliminary action by providing positioning elements on the individual plates before the welding process. These positioning elements ensure that the plates are correctly aligned and positioned during assembly, eliminating the need for high-precision positioning during welding and thereby reducing production complexity while maintaining manufacturing precision.
3Productivity
If the weld pool is rapidly cooled during welding, then the welding process is faster, but end craters and star-shaped cracks occur that compromise joint integrity
Solution Approach 1:
The patent changes the thermal parameters of the welding process by controlling the cooling rate of the weld pool. By optimizing welding speed and power parameters, the process achieves high productivity while preventing rapid cooling that would cause end craters and star-shaped cracks, thereby maintaining joint integrity.
Solution Approach 2:
The patent converts the potentially harmful rapid cooling effect into a beneficial controlled solidification process. By carefully managing the cooling rate, the weld pool solidifies in a way that creates a smooth, crack-free end region that enhances joint integrity rather than creating weak points for star-shaped cracks.
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
The design effectively reduces the occurrence of cracks and leaks in the welded joints, leading to improved durability and extended service life of the separator plates under operational pressures.
Implementation Method 1
The separator plate comprises a first individual plate and a second individual plate which are connected to the first individual plate by means of a welded joint
Data Source
AI summary
The present disclosure relates to a separator plate for an electrochemical system, comprising first and second individual plates connected by means of a welded joint, each individual plate comprising at least one through-opening for passage of a fluid, a flow field, a distribution or collecting region which fluidically connects the through-opening to the flow field, and a transition region which is arranged between the flow field and the distribution or collecting region, wherein the welded joint is arranged in the flow field and/or in the transition region, wherein the welded joint extends longitudinally from a first end located in a first end region to a second end located in a second end region, wherein the welded joint forms an end crater between the first and second ends and the end crater is spaced from the first and second ends.