Separator Plate Web Structure for Stronger Welded Channel Crossings
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for connecting separator plates in electrochemical systems, particularly where channels intersect, often result in weak connections due to positioning inaccuracies, leading to tears or energy concentration issues, which can cause system failure and high production rejects.
Innovation Solution
A separator plate design with a web configuration that allows for a larger contact zone by lowering the web at intersection points and using a welded connection with curved portions to stabilize the end regions, reducing the likelihood of peeling or tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding methods are used to connect individual plates at channel crossing regions, then connection strength may be sufficient, but positioning inaccuracies cause weak connections, tears, or burning through the plates
Solution Approach 1:
The patent applies preliminary action by extending the web structure beyond the channel crossing point to create a larger contact zone before welding occurs. This pre-positioned extension ensures that even with positioning variations, the welding instrument can establish a strong connection on the extended web surface, preventing weak connections and plate damage.
Solution Approach 2:
The patent transitions from a two-dimensional channel crossing to a three-dimensional structure by extending the web vertically beyond the channel plane. This dimensional change creates additional welding surface area and tolerance buffer, allowing stronger connections despite positioning inaccuracies in the horizontal plane.
2Stability of the object's composition
If the web is lowered to create a larger contact zone, then connection stability improves, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the web structure into distinct functional zones: the original channel-defining web portion and the extended contact zone portion. This segmentation allows the structure to serve multiple functions - channel formation and connection stabilization - while maintaining manufacturing feasibility through modular design.
3Strength
If the welded connection includes curved portions to stabilize end regions, then resistance to peeling and tearing improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies curvature to the welded connection by incorporating curved portions that extend along the web. This curved geometry distributes stress more effectively compared to straight connections, enhancing resistance to peeling and tearing forces while the extended web provides tolerance for positioning variations.
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 enhances the stability and durability of the separator plate connections, reducing production rejects and extending the system's service life by distributing stress and increasing the connection area.
Implementation Method 1
a rear side of the first individual plate, said rear side facing the second individual plate, in the region of the lowered portion or in a region adjoining the lowered portion, to be connected to a rear side of the base of the second channel, said rear side facing the first individual plate, in the contact zone of the individual plates by means of a welded connection
Data Source
AI summary
A separator plate for an electrochemical system comprising a first individual plate which comprises two first channels for conducting media which run next to one another and which are separated from one another at least in sections by a web formed between the first channels. The web comprising a lowered portion and a rear side of the base of the lowered portion is connected to a rear side of the base of the second channel in the contact zone of the individual plates via a welded connection. The welded connection comprises a first end region and a first curved portion, wherein the first curved portion runs, and is curved, in such a way that a virtual straight line running perpendicularly through the first end region intersects the welded connection at least two times.