Manufacturing metallic bipolar plate fuel cells through rubber pad forming process

Elyasi, Majid; Khatir, Farzad Ahmadi; Hosseinzadeh, Morteza

doi:10.1007/s00170-016-9297-6

Cited by 51 publications

(21 citation statements)

References 9 publications

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“…Within a turning and milling centre (NILES N20 MC2000, Chemnitz, Germany), pockets had to be machined in both of the roller tools, for the inserts with the geometrical structures of the bipolar plate channels (Figure 1). deep drawing [2,3], deep drawing with rigid dies [4,5], rubber pad forming [6,7] or special technologies like casting [8] and single point incremental forming [9]. While the mentioned manufacturing technologies of metallic bipolar plates already work well for small lot sizes [10], these methods have not been established for mass productions yet.…”

Section: Methodsmentioning

confidence: 99%

“…Furthermore, several restrictions were made regarding the plate design to achieve a compromise between high energy density, flow conditions of cell media and a reduced assembly space [1]. Several technologies are available to form metallic bipolar plates, such as hydromechanical deep drawing [2,3], deep drawing with rigid dies [4,5], rubber pad forming [6,7] or special technologies like casting [8] and single point incremental . While the mentioned manufacturing technologies of metallic bipolar plates already work well for small lot sizes [10], these methods have not been established for mass productions yet.…”

Section: Introductionmentioning

confidence: 99%

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Manufacturing of Metallic Bipolar Plate Channels by Rolling

Bauer

Härtel

Awiszus

2019

JMMP

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Producing metallic bipolar plates for Proton Exchange Membrane (PEM) fuel cells by forming is still a topic of research. So far, it has mainly been applied for small batches, but it offers substantial advantages regarding both costs and installation space compared to the established graphite based solutions. One new possibility for an efficient manufacturing process of these metallic bipolar plates is the forming by rolling. For the first time, this technology was used for relevant industrial scale channel geometries. By the use of an experimental rolling mill, 0.1 mm thick 316L (1.4404) stainless steel foils were roll-formed to achieve previously designed channel geometries within one rolling pass. The conducted experiments show promising results regarding the forming accuracy and the shape of the channel cross-sections. With the aim for a proof of concept in the beginning and a subsequent optimization of the process, a numerical simulation was set up prior to the real experiments and later calibrated with the experimental forming results. This calibrated model was used for further improvements of the process with the objective at reducing wrinkles and distortion. The investigation of this new process method for the manufacturing of metallic bipolar plates shows enormous potential and can lead to a more efficient and cheaper production.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Manufacturing of Metallic Bipolar Plate Channels by Rolling

Bauer

Härtel

Awiszus

2019

JMMP

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“…Based on the nite element simulation results, the parameters with the best forming results were selected. [25] Different molds are manufactured according to the channel parameters numbered No.7 and No.10.…”

Section: Forming Experimentsmentioning

confidence: 99%

Shape and Position Design of Two-Step Micro-Channel on Plate During Rubber Pad Forming Process Based on Simulation

Teng

Wang

et al. 2020

Preprint

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Abstract Rubber pad forming is an advanced processing technology. The micro-channel is formed on the plate by both rubber pad and the metal mold. With the development of micro-channel, a two-step micro-channel has been applied in more and more fields. However, little attention was given to the geometric design and forming process of this unique channel. In this paper, the process of forming multi-row two-step micro-channels on plate by rubber pad forming is studied. At the same time, the length, width, height ratio and the edge chamfer of two-step micro-channel are discussed as the main parameters of geometry. The number and distance of the second-step structures are also studied in this paper. The influence of these geometric parameters on the forming results is analyzed in the finite element simulation. The plates are designed according to these geometric parameters and structures. Moreover, a novel shape and position design of two-step micro-channel are provided. In addition, forming experiments are also carried out for further study. Finally, a design strategy is provided by forming results in conclusions.

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“…Typical manufacturing methods in the current state of the art are mechanical deep drawing [4][5][6][7][8][9][10][11], hydroforming [4,12] or rubber pad forming [4,[13][14][15]. The basic objective of all manufacturing processes is a precise and accurate forming result of the desired channel cross section profile.…”

Section: Forming and Formability Of Metallic Channel Platesmentioning

confidence: 99%

Method for Analytical Calculation of the Formability from Metallic Bipolar Plates

Keller

Bauer

Unwerth

et al. 2019

JMMP

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The constructive design of a flow field layout and the channel cross section parameters from a metallic half- or bipolar plate can have a significant influence on the performance characteristics of a fuel cell. One important aspect in the dimensioning of the channel geometry of half plates is the technical forming feasibility. In this article, first an equation is presented, which enables an analytical calculation of the channel parameters. Hereby, continuing calculations with parameter variations will be possible. Furthermore, the formability of the channel geometry of metallic half plates is evaluated through numerical and experimental investigations. Based on the results, an analytical model approach will be derived that enables an appraisal of the formability from channel cross section contours in an early development state. As a final step, the results of the numerical investigations and the analytical calculation method are compared and evaluated with the results of experimental investigations and other publications. It will be shown, that the derived analytical model approach has a good approximation compared to the effects and results from the numerical and experimental analysis. In particular, the assessment of whether a channel cross section can be manufactured safely is a result with high probability of the analytical model approach. Imprecisions happen, especially in variants with extreme geometries, for example, with very small radii or a huge channel depth. For this kind of variations, the analytical model behaves too sensitively, which makes it more difficult to estimate the damage effects. However, at an early development state, the analytical model offers a good method to get a pre-evaluation of the formability of channel cross sections with a simultaneous parameter variation possibility.

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Manufacturing metallic bipolar plate fuel cells through rubber pad forming process

Cited by 51 publications

References 9 publications

Manufacturing of Metallic Bipolar Plate Channels by Rolling

Manufacturing of Metallic Bipolar Plate Channels by Rolling

Shape and Position Design of Two-Step Micro-Channel on Plate During Rubber Pad Forming Process Based on Simulation

Method for Analytical Calculation of the Formability from Metallic Bipolar Plates

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