Nested Separator Plate Channels Without Bonded Joints
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Solution Overview
Problem
Existing separator plates in electrochemical systems face challenges such as complex manufacturing processes due to small radii of curvature, which can lead to cracking and reduced service life, and require material bonding for connection, increasing weight and installation space.
Innovation Solution
A separator plate design featuring two individual plates with wave-like channels that nest into each other, eliminating the need for material bonding in the channel regions, allowing for a form and force fit connection, reducing the intermediate space and weight, and improving manufacturing simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If small radii of curvature are used at channel bottom corners to enable material bonding, then the plates can be connected by welding or adhesive, but cracks form more quickly during use or manufacture, reducing service life
Solution Approach 1:
The patent applies large radii of curvature at the channel bottom corners instead of small radii, which eliminates stress concentration points that cause cracking. The rounded corners with large radii distribute mechanical stresses more evenly, preventing crack formation during manufacturing and operation, thereby extending service life while maintaining connection integrity.
Solution Approach 2:
The patent designs the channel bottoms with inherently crack-resistant features (large radii of curvature) before assembly, providing built-in protection against stress concentrations. This preliminary design approach prevents crack initiation rather than addressing it after failure begins, ensuring long-term durability.
2Strength
If individual plates are connected by material bonding (welding, adhesive, brazing), then the separator plate can be formed, but the weight and installation space increase
Solution Approach 1:
The patent employs a nested configuration where one plate is inserted into another plate, creating a form-fit connection. This nesting arrangement eliminates the need for additional bonding materials (adhesives, welds, brazing), thereby reducing the overall weight of the separator plate assembly while maintaining structural integrity through the interlocking geometry.
Solution Approach 2:
The patent extracts the bonding material (adhesive, weld, brazing) from the connection process entirely. By using a pure mechanical form-fit connection where plates nest into each other, the solution removes unnecessary weight-contributing materials while achieving the required connection strength through geometric interlocking.
3Ease of manufacture
If small radii of curvature are used at channel corners, then material bonding can be implemented, but the manufacturing complexity increases and cracks form more quickly
Solution Approach 1:
The patent uses large radii of curvature at channel corners instead of small radii, which simplifies the manufacturing process. Large radii are easier to form using conventional machining and forming operations, reducing manufacturing complexity while eliminating the stress concentration issues associated with sharp corners and small radii.
4Weight of moving object
If the coolant chamber size is reduced through nested plates, then weight is reduced, but cooling fluid distribution must be enhanced
Solution Approach 1:
The patent incorporates wave-like channels with smooth curved transitions, which enhance cooling fluid distribution through the reduced coolant chamber. The curved geometry promotes uniform flow distribution and prevents dead zones, ensuring effective cooling despite the compact size and reduced fluid volume.
Data Source
AI summary
The present disclosure relates to a separator plate for an electrochemical system, comprising a first individual plate and a second individual plate connected to the first individual plate, wherein channels of the individual plates are nested in each other. The present disclosure also relates to an arrangement for an electrochemical system, comprising a plurality of separator plates.