Sheet Press Patterning for Large Electrolyser Plate Flow Fields
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Solution Overview
Problem
Conventional presses struggle to produce large deformation patterns on metal sheets, particularly in electrolyser and fuel cell plates, due to increasing forces required with larger sizes or more depressions, making it economically unfeasible and imprecise.
Innovation Solution
The method involves breaking down the deformation pattern into sub-areas with identical pattern units, using a tool unit with forming dies to form each unit in a single stroke, and conveying the sheet between strokes to complete the pattern, reducing process forces and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the deformation pattern size or number of depressions is increased, then the functionality and coverage area of electrolyser plates are improved, but the forces required for deformation increase significantly making single-stroke production infeasible
Solution Approach 1:
The deformation pattern is divided into multiple identical pattern units arranged in a sequence. Instead of forming all pattern units simultaneously in one stroke, the press forms them sequentially across multiple strokes. Each stroke forms a subset of pattern units, breaking down the total deformation force requirement into manageable portions that can be applied incrementally.
Solution Approach 2:
The press operates in periodic cycles, performing the deformation operation repeatedly across multiple strokes. Each stroke constitutes one period where a portion of the pattern units is formed, then the press resets and repeats the operation. This periodic action allows the system to manage large deformation patterns by distributing the force application across time rather than concentrating it in a single stroke.
2Ease of manufacture
If conventional presses are used for large deformation patterns, then existing equipment can be utilized, but production precision and economic feasibility deteriorate
Solution Approach 1:
By segmenting the deformation pattern into multiple small pattern units that are formed sequentially, each individual deformation operation involves smaller forces and more manageable dimensions. This segmentation allows conventional presses with limited force capacity to achieve precise deformation of each pattern unit, while the cumulative effect produces the complete large-scale pattern with overall high precision.
3Productivity
If single-stroke deformation is used for complete patterns, then production speed is maintained, but the maximum pattern size is limited by press force capacity
Solution Approach 1:
The press operates continuously across multiple strokes, with each stroke contributing to the formation of the complete deformation pattern. Rather than requiring one extremely long stroke that would exceed force capacity, the useful deformation action continues uninterrupted across multiple shorter strokes, each forming a portion of the pattern. This continuous multi-stroke process maintains high productivity while enabling much larger pattern areas than single-stroke methods.
Data Source
AI summary
A method and a press for introducing a deformation pattern into a sheet uses at least one tool unit for producing an electrolyser plate or fuel cell plate, wherein the deformation pattern in at least one sub-area has a plurality of identical pattern units lying beside one another with a pattern spacing in at least one pattern direction, and the press for forming only the sub-area comprises a tool unit, in which an upper and a lower forming die are arranged, with the interacting deformation structures of which at least one pattern unit of a sub-area is formed in a single stroke of the tool unit in the sheet guided between the forming dies, and with each stroke of a predetermined total number, the pattern introduced into the sheet is supplemented by at least one introduced pattern unit.