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WO2023110152A1 - Paire de matrices de fabrication de plaque 3d par formage à la presse, matrice parmi la paire de matrices et procédé de formage à la presse à l'aide de la paire de matrices - Google Patents

Paire de matrices de fabrication de plaque 3d par formage à la presse, matrice parmi la paire de matrices et procédé de formage à la presse à l'aide de la paire de matrices Download PDF

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Publication number
WO2023110152A1
WO2023110152A1 PCT/EP2022/025577 EP2022025577W WO2023110152A1 WO 2023110152 A1 WO2023110152 A1 WO 2023110152A1 EP 2022025577 W EP2022025577 W EP 2022025577W WO 2023110152 A1 WO2023110152 A1 WO 2023110152A1
Authority
WO
WIPO (PCT)
Prior art keywords
die
plate
dies
pair
die pair
Prior art date
Application number
PCT/EP2022/025577
Other languages
English (en)
Inventor
Giel ROMPEN
Original Assignee
Robert Bosch Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Robert Bosch Gmbh filed Critical Robert Bosch Gmbh
Publication of WO2023110152A1 publication Critical patent/WO2023110152A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D13/00—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form
    • B21D13/02—Corrugating sheet metal, rods or profiles; Bending sheet metal, rods or profiles into wave form by pressing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0247—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the form
    • H01M8/0254—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the form corrugated or undulated
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • H01M8/0258—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
    • H01M8/026—Collectors; Separators, e.g. bipolar separators; Interconnectors characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant characterised by grooves, e.g. their pitch or depth

Definitions

  • the present invention relates to a die pair consisting of an upper die and a lower (counter) die for press forming plate material between such upper and lower dies, perpendicular to the main plane thereof, which press-forming method is also known as embossing or 3D shaping in general.
  • press-forming method is also known as embossing or 3D shaping in general.
  • one die of the die pair is moved relative to the other die of the pair that is fixed in place, which moveable die is commonly referred to as a punch.
  • Press-formed, i.e. 3D-shaped plates are used in many applications, such as in construction, in heat exchange devices and in electrochemical devices, in particular as so-called fluid distribution plates in such devices that are also referred to as separator plates or bipolar plates.
  • a flat, relatively thin plate is used as a starting material, into which corrugations are pressed perpendicular to the main plane of the plate.
  • these corrugations constitute a so-called flow field for fluid, composed of channels located between relatively protruding islands, ridges, etc. that are provided on a relatively fine scale in the main plane of the plate (i.e. small corrugation pitch) and on a relatively large scale perpendicular thereto (i.e. large corrugation depth/height). That is to say that a width dimension of a single channel of the plate corrugations is typically small compared to its depth or height dimension, while all of these three dimensions are multiples of the plate thickness.
  • the starting material can be a plastic, but in many of the said applications (sheet) metal is the preferred starting material.
  • the channels defined by the plate corrugations carry reactants and/or coolant along a so-called active area of the device to and from through-holes in the plate for the supply and discharge thereof.
  • the channels of the plate corrugations allow fluid communication with an electrode or other porous layer, whereas the ridges thereof supports and fixates such porous layer in the electrochemical device.
  • the plate corrugations can also serve to contain a sealing or gasket between the plate and the porous layer or between two adjoining plates. In a typical manufacturing process of the separator plate, the said through-holes in the starting material are pierced through first.
  • the said plate corrugations are created by press forming the fluid distribution plate between the dies of the said die pair.
  • the outer circumference of the fluid distribution plate is cut, for example by means of laser cutting or blanking.
  • the punch and counter punch that are applied in such well-known fine-blanking process may serve as the presently considered die pair for 3D-shaping.
  • the working surface -being the surface facing and/or engaging the plate- of at least one die of the die pair is thereto provided with a surface profile defined by relatively raised and relatively recessed parts of the respective die, corresponding to the desired 3D shape of the plate.
  • rubber pad (press) forming only one die of the die pair is provided with such profiled working surface.
  • the working surfaces of both dies of the die pair are provided with respective surface profiles that are mutually complementary to one another, such that the raised parts of one die correspond with the recessed parts of the other die and vice-versa. More specifically, such complementary die pair can be designed as a so- called closed tooling, open tooling, or semi-closed tooling.
  • the dies of the die pair are designed to engage the plate directly opposite one another, at least in an ultimate, i.e. fully closed position of the press-forming tooling including such die pair during the press forming of the plate.
  • the material of the plate is compressed somewhat between the dies, such that it can plastically flow transversely thereof.
  • the top and bottom sections of the corrugations that typically remain essentially oriented in the main plane of the plate
  • This specific setup of press forming with the closed tooling can counteract a tearing of the plate material, i.e. can enable a favourably relatively sharp transition/sharp curvature between the wall sections and the top and bottom sections of the corrugations.
  • the relatively high forces exerted by and between the dies of the closed tooling can result in relatively high tool wear.
  • the USA patent US 9,364,883 B2 describes a variant of the closed tooling.
  • the said wall sections of the corrugations are compressed between the dies of the die pair, rather than the top and bottom sections thereof.
  • the corrugation depth can be increased without tearing of the plate material.
  • US 10,150,152 B2 describes a fully closed tooling, wherein both the top and bottom sections and the wall sections of the corrugations are compressed between the dies. Both these latter two variants, however, will be accompanied by even higher forces and more wear than the aforementioned, conventional closed tooling.
  • the dies of the die pair are designed to engage the plate only through the said raised parts of the respective working surfaces thereof, even in an ultimate, i.e. closest together position thereof in the press-forming tooling during the press forming of the plate.
  • the plate is not compressed, but rather is bent and stretched by and around the raised parts of the dies.
  • This specific setup of press forming can reduce tool wear.
  • a known limitation of the open tooling is that the corners/transitions of the corrugations between the wall sections and the top and bottom sections thereof, cannot be as sharply curved when using the open tooling, as compared to the closed tooling.
  • top and bottom sections of the corrugations are engaged only on the (concave) inside thereof, i.e. are engaged by only one of the dies of the die pair, these will be more or less convexly/concavely shaped when using the open tooling. Therefore, if relatively sharp corrugation corners are required and/or if relatively flat top and bottom corrugation sections are required, the closed tooling is to be preferred. Nevertheless, also when using the closed tooling, the plate corrugations will necessarily deviate from a theoretically rectangular shape, due to bending contraction in press forming and/or elastic spring-back after press forming.
  • the dies of the die pair are designed such that the raised parts of one die form a closed tooling part and the raised parts of the other die form an open tooling part. That is to say that in the said ultimate, i.e. closest together position of the dies during the press forming of the plate, the plate is compressed only locally between the raised parts of the said one die and the recessed parts of the said other die, whereas the raised part of the said other die are also pressed into the plate, however without contacting the recessed parts of the said one die, i.e. without compressing the plate at these locations.
  • a compromise is sought between the aspects of closed and open tooling mentioned above.
  • the present invention aims to improve upon the known press-forming method and the closed or the semi-closed tooling thereof.
  • the present invention aims to improve upon the flatness of the top and/or bottom sections of the resulting plate corrugations, specifically in relation to relatively thin (and thus relatively easy to tear) metal plate in combination with corrugations on a relatively fine scale.
  • the present invention specifically relates to fluid distribution plates having a thickness of 0.05 to 0.5 mm, having a corrugation pitch of 1 to 10 mm and having a corrugation depth that exceeds the plate thickness by a factor of 2 to 8.
  • Such flatness of the corrugation top and/or bottom sections is sought after as this can improve the mechanical and electrical contact between the corrugated plate and the said porous layer or another, i.e. adjoining plate.
  • At least one of the relatively raised parts of the working surfaces of the dies of the die pair is provided with a protruding edge that protrudes beyond a central section of a top surface of that respective relatively raised part, located adjacent to such protruding edge.
  • a protruding edge that protrudes beyond a central section of a top surface of that respective relatively raised part, located adjacent to such protruding edge.
  • such central section of the respective relatively raised part is recessed relative to a corner section thereof.
  • the said bending contraction and/or the said elastic spring-back of the respective corrugation corner are favourably reduced.
  • the flatness of the (outside of the) top and/or bottom section of the respective plate corrugations can be favourably improved and/or the respective plate corrugations can be favourably more rectangularly shaped.
  • such protruding edge is provided on both sides of that one raised part, more preferably on both sides of all of the relatively raised parts of the working surfaces of the dies in question and most preferably on both sides of all of the raised parts of the working surfaces of both dies of the die pair.
  • a height difference between the said protruding edge of a respective raised part and the adjacent, lower lying, central section of the top surface thereof amounts to between 10% and 60% of the plate thickness, in particular to between 20% to 40% of such thickness, more in particular to about 30% such thickness.
  • a peak i.e. most protruding part of the said protruding edge is shaped as a flat surface, preferably extending in parallel with a corresponding recessed part of the working surface of the opposing die of the die pair, the bottom surface of which recessed part is likewise shaped as a flat surface.
  • the protruding edge has sufficient strength for it to be formed cost-effectively by abrasively removing material at the location of the said relatively lower lying, central section of the top surface of the respective raised part, such as by milling.
  • milling are, for instance, electrical discharge machining EDM and laser ablation, which latter processes typically allow the said protruding edge to be shaped with smaller and/or sharper details compared to milling.
  • Figure 1 schematically depicts a typical example of a known fluid distribution plate defining fluid channels on both sides thereof by virtue of being provided with corrugations;
  • Figure 2 is a schematically drawn, cross-sectional view of a part of a die pair of the known press-forming tooling prior to press forming the corrugated plate, illustrating the surface profile of the working surface of the dies thereof;
  • Figure 3 provides the same cross-sectional view of the known die pair as in figure 2 however in a fully closed position of the press-forming tooling;
  • Figure 4 is a photograph of a cross-section of a thin, corrugated plate that is typically obtained with the known press-forming tooling;
  • Figure 5 is a schematically drawn, cross-sectional view of a part of a novel die pair in accordance with the invention, illustrating the surface profile of the working surfaces thereof;
  • Figure 6 provides the same cross-sectional view of the novel die pair as in figure 5 however in a fully closed position of a press-forming tooling constituted thereby;
  • Figure 7 represents a cross-section of a thin, corrugated plate that is obtained with the die pair according to the invention.
  • Figure 8 schematically illustrates several principle shapes of a protruding edge of a raised part of a die of the die pair according to the invention.
  • FIG 1 a generic example of fluid distribution plate 1 is illustrated, such as is used as a separator in a stack of electrochemical cells.
  • the fluid distribution plate 1 has flat outer rim 2 and a central, so-called active area 3 that is 3D-shaped.
  • the outer rim 2 of the plate 1 is provided with circular holes 4 for accommodating bolts that hold the stack together and with oblong holes 5 for the supply and discharge of (fluid) reactants and/or coolant to and from the said active area 3 of the plate 1.
  • the active area 3 is composed of multiple channels and multiple ridges oriented in parallel.
  • the channels on one main side of the plate 1 represent the ridges on the other main side thereof and vice-versa.
  • the 3D-shape of the active area 3 of the fluid distribution plate 1, i.e. the concavely shaped channels 6 and the convexly-shaped ridges 7 thereof is typically created by press forming plate material 10 between an upper die 20 and a lower die 21 of a die pair, which dies 20, 21 are thereto moved together with the plate material 10 placed therebetween, as schematically illustrated in figures 2 and 3.
  • the dies 20, 21 of the die pair and the plate material 10 are illustrated in a cross-section of a relevant part thereof.
  • the working surface 22 -being the surface 22 that faces and at least in part engages the plate material 10- of both dies 20, 21 is provided with a surface profile that is defined by relatively recessed parts 23 of the dies 20, 21, located between relatively raised parts 24 thereof.
  • the working surface 22 of the dies 20, 21 are mutually complementary in the sense that the raised parts 24 of one of the dies 20, 21 can fit into the recessed parts 23 of the respective other one die.
  • the known raised parts 24 are provided with a flat top surface and the known recessed parts 23 are provided with a flat bottom surface.
  • the plate material 10 is permanently deformed, i.e. is plastically bent and stretched around the said raised parts 24 of the working surfaces 22 thereof.
  • the dies 20, 21 of the die pair are illustrated in their ultimate position of press-forming, wherein the corrugations of the active area 3 of the fluid distribution plate 1 is completely formed.
  • a mutual separation S remaining there between can be larger than a thickness T of the plate material 10 indicated in figure 2 (so-called open tooling; not illustrated), or equal to or marginally smaller than such thickness T (so-called closed tooling; illustrated in figure 3).
  • Figure 4 provides a photographic representation of a cross-section of the active area 3 of the fluid distribution plate 1 obtained in practice with the above-described, known press-forming method and press-forming tooling. In figure 4, three limitations of such known method and tooling are observable
  • the arrow A indicates an area, in particular a corrugation corner 25, where a substantial bending contraction occurred in thickness direction of the fluid distribution plate 1.
  • the fluid distribution plate 1 is locally weakened and a minimum bending radius and/or maximum angle disadvantageously applies to such corrugation corner 25 in the design of the fluid distribution plate 1.
  • the arrow B indicates an area, in particular a bottom section 26’ of a respective corrugation, where the corners 25’ of that respective corrugation mutually overlap.
  • the outside of the said bottom section 26’ is disadvantageously curved, i.e. does not include a flat middle part that is typically preferred or even required in the application.
  • corner overlap can always be avoided.
  • design limitation is undesirable as a matter of principle.
  • the arrow C indicates an area, in particular a top section 26 of a respective corrugation, where the corner 25 of that respective corrugation disadvantageously shows more elastic spring-back after press forming than the corner 25’ on the opposite side of a wall section 27 of that respective corrugation.
  • the top section 26 and the bottom section 26’ of respectively adjacent corrugations are disadvantageously mutually oriented at an angle rather than in parallel.
  • the present invention aims to improve the known method for press forming plate material 10.
  • the present invention aims to address the above-mentioned limitations of the known press-forming and to at least improve upon the flatness of the top and/or bottom section 26; 26’ of the plate corrugations.
  • the present invention proposes a novel design of at least one of the dies 20, 21 of the die pair, which novel design is illustrated in figures 5 and 6.
  • Figures 5 and 6 provide a cross- sectional view of a press-forming die pair -and of the plate material 10 that is (to be) shaped thereby- similar to those provided by figures 2 and 3, however, with the dies 20, 21 thereof being designed in accordance with the present invention.
  • the raised parts 24 of the working surfaces 22 of the dies 20, 21 of the die pair are provided with protruding edges 30 that extend beyond a flat top surface 31 of a respective raised part 24 in the height direction thereof.
  • the novel dies 20, 21 of the die pair according to the present invention are illustrated in their ultimate position of press-forming, wherein the corrugations of the active area 3 of the fluid distribution plate 1 is completely formed.
  • a mutual separation S remaining there between when measured at the location of the said top surface 31 of the raised part 24, is essentially equal to the thickness T of the plate material 10, whereas when measured at the location of the said protruding edge 30 of the raised part 24, such mutual die separation is smaller than such plate thickness T.
  • the separation of the dies 20, 21 remaining at the location of the said protruding edge 30 in the fully closed position of the press-forming tooling amounts to approximately 50% of the plate thickness T.
  • the height difference between the protruding edge 30 and the lower lying top surface 31 of the raised parts 24 of the dies 20, 21 of the novel die pair also amounts to approximately 50% of the plate thickness T.
  • This latter value of 50% is on the higher end of the applicable range for the relative height of the protruding edges 30, to be able to clearly illustrate this novel design feature according to the present invention.
  • a relative height of the protruding edges 30 amounting to between one quarter and one third of the plate thickness T will typically be optimal.
  • Figure 7 illustrates the corrugations that are obtainable by press forming with the die design according to the present invention in a partial cross-section of the resulting, 3D-shaped plate 1.
  • the said relative height of the protruding edges 30 of the raised die parts 24 used to press form the corrugated plate 1 amounted to 0.3 times the nominal thickness T of the plate 1.
  • Figure 8 schematically illustrates several possible detailed designs of the dies 20, 21 of the die pair according to the invention in a cross-section of the raised part 24 thereof and zoomed-in on the protruding edge 30 of that raised part 24.
  • the reference numbers 33a-d indicate several principle contours, i.e. surface shapes of the protruding edge 30, as part of the working surface 22 of the respective die 20; 21 that extends between the (lower lying) top surface 31 of the respective raised part 24 and a respective side surface 32 thereof.
  • the respective part 33a of the contour 33a-d of such protruding edge 30 is preferably convexly curved. Beyond such most protruding part P of the protruding edge 30, i.e. descending towards the top surface 31 of the raised part 24, the contour 33a-d thereof can be convexly curved as well, as illustrated by the dashed-dotted line 33b in figure 8. Nevertheless, the protruding edge 30 is preferably created by abrasively machining (e.g. milling) the respective raised part 24 at the location of the top surface 31 thereof.
  • a machining radius i.e. the radius of concave curvature of that solid line 33c, preferably amounts to between 50% and 250% of a radius of curvature of the said convexly curved part 33a of the contour 33a-d of the protruding edge 30.
  • the highest part P of the protruding edge 30 is preferably represented by a flat part 33d of such contour 33a-d, extending in the width direction thereof, i.e. essentially in parallel with the top surface 31 thereof.
  • a flat part 33d By such flat part 33d the mechanical strength and/or wear resistance of the protruding edge 30 is remarkably increased, as may be required for the said milling of the raised part 24 and/or for the actual use of the die 20; 21 in press forming. Nevertheless, the extend of such flat part 33d in width direction can remain relatively small.
  • such extend of the flat part 33d preferably amounts to between 5% and 50% of the radius of curvature of the said convexly curved part 33a of the contour 33a-d of the protruding edge 30.

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  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

La présente invention se rapporte à une paire de matrices (20, 21), constituée d'une matrice supérieure (20) ou poinçon et d'une matrice inférieure ou contre-matrice (21) permettant le formage à la presse d'un matériau de plaque (10) entre lesdites matrices supérieure et inférieure (20, 21), dont au moins une matrice (20 ; 21) présente une surface de travail profilée (22) dotée de parties relativement surélevées (24) et de parties relativement en retrait (23). Selon la présente invention, lesdites parties relativement surélevées (24) sont munies chacune d'un bord saillant (30) entre une surface supérieure (31) et une surface latérale de ladite partie relativement surélevée (24).
PCT/EP2022/025577 2021-12-19 2022-12-16 Paire de matrices de fabrication de plaque 3d par formage à la presse, matrice parmi la paire de matrices et procédé de formage à la presse à l'aide de la paire de matrices WO2023110152A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL2030189 2021-12-19
NL2030189A NL2030189B1 (en) 2021-12-19 2021-12-19 A die pair for manufacturing a 3d-shaped plate by press forming, a die of the die pair and a press-forming method using the die pair

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Publication Number Publication Date
WO2023110152A1 true WO2023110152A1 (fr) 2023-06-22

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PCT/EP2022/025577 WO2023110152A1 (fr) 2021-12-19 2022-12-16 Paire de matrices de fabrication de plaque 3d par formage à la presse, matrice parmi la paire de matrices et procédé de formage à la presse à l'aide de la paire de matrices

Country Status (2)

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NL (1) NL2030189B1 (fr)
WO (1) WO2023110152A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202022107287U1 (de) * 2022-12-29 2024-04-10 Reinz-Dichtungs-Gmbh Separatorplatte, und Werkzeugpaar zur Herstellung einer derartigen Separatorplatte

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995016287A1 (fr) 1993-12-10 1995-06-15 Ballard Power Systems Inc. Plaque estampee pour l'ecoulement du champ de propagation du fluide des piles electrochimiques a combustible
EP3015182A1 (fr) * 2013-06-25 2016-05-04 Nissan Motor Co., Ltd. Dispositif et procédé pour former un substrat en plaque mince
US9364883B2 (en) 2010-09-02 2016-06-14 Toyota Boshoku Kabushiki Kaisha Method of producing a separator
US20180154417A1 (en) * 2016-12-06 2018-06-07 Toyota Boshoku Kabushiki Kaisha Method and apparatus for forming metal sheet
US20180154416A1 (en) * 2016-12-07 2018-06-07 Toyota Boshoku Kabushiki Kaisha Sheet metal forming method and apparatus
JP2018094579A (ja) * 2016-12-12 2018-06-21 トヨタ自動車株式会社 金属板のプレス成形方法

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995016287A1 (fr) 1993-12-10 1995-06-15 Ballard Power Systems Inc. Plaque estampee pour l'ecoulement du champ de propagation du fluide des piles electrochimiques a combustible
US9364883B2 (en) 2010-09-02 2016-06-14 Toyota Boshoku Kabushiki Kaisha Method of producing a separator
EP3015182A1 (fr) * 2013-06-25 2016-05-04 Nissan Motor Co., Ltd. Dispositif et procédé pour former un substrat en plaque mince
US20180154417A1 (en) * 2016-12-06 2018-06-07 Toyota Boshoku Kabushiki Kaisha Method and apparatus for forming metal sheet
US20180154416A1 (en) * 2016-12-07 2018-06-07 Toyota Boshoku Kabushiki Kaisha Sheet metal forming method and apparatus
US10150152B2 (en) 2016-12-07 2018-12-11 Toyota Boshoku Kabushiki Kaisha Sheet metal forming method and apparatus
JP2018094579A (ja) * 2016-12-12 2018-06-21 トヨタ自動車株式会社 金属板のプレス成形方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE202022107287U1 (de) * 2022-12-29 2024-04-10 Reinz-Dichtungs-Gmbh Separatorplatte, und Werkzeugpaar zur Herstellung einer derartigen Separatorplatte

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