WO2025218316A1 - 燃料电池金属极板的制备方法及金属极板多步成形生产线 - Google Patents
燃料电池金属极板的制备方法及金属极板多步成形生产线Info
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- WO2025218316A1 WO2025218316A1 PCT/CN2025/076182 CN2025076182W WO2025218316A1 WO 2025218316 A1 WO2025218316 A1 WO 2025218316A1 CN 2025076182 W CN2025076182 W CN 2025076182W WO 2025218316 A1 WO2025218316 A1 WO 2025218316A1
- Authority
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- WIPO (PCT)
- Prior art keywords
- metal plate
- forming
- stamping
- electrical
- electrode
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/88—Processes of manufacture
- H01M4/8875—Methods for shaping the electrode into free-standing bodies, like sheets, films or grids, e.g. moulding, hot-pressing, casting without support, extrusion without support
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/88—Processes of manufacture
- H01M4/8878—Treatment steps after deposition of the catalytic active composition or after shaping of the electrode being free-standing body
- H01M4/8882—Heat treatment, e.g. drying, baking
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
Definitions
- the present application relates to the field of fuel cells, and in particular to a multi-step forming production line for metal plates based on an electrical treatment modification effect and a process thereof, and in particular to a preparation method for fuel cell metal plates and a multi-step forming production line for metal plates.
- Hydrogen energy is a key strategic tool for promoting the green transformation of the global energy industry.
- Proton exchange membrane fuel cells are a key technology for hydrogen energy utilization, and high power, long life, and high performance are the development trends of fuel cells.
- bipolar plates feature submillimeter-scale microfluidic channels. The refinement of these channels significantly impacts the fuel cell's power generation efficiency, reliability, and service life.
- metal bipolar plates offer multiple advantages, including reduced thickness, low cost, superior mechanical properties, and excellent electrical and thermal conductivity. They have become a major trend in fuel cell manufacturing technology.
- bipolar plates need to have finer flow channel structures and higher flow channel depth-to-width ratios.
- the forming performance bottleneck of ultra-thin metal substrates will cause them to crack prematurely during the stamping process, restricting the high-performance development of fuel cells.
- extensive innovations have been made in the forming methods of metal bipolar plates at home and abroad.
- new laboratory-level processes such as electromagnetic high-speed forming and high-temperature forming can effectively improve the forming limit of metal plates, they all exhibit low production efficiency and poor compatibility with existing bipolar plate production lines, limiting their application in actual production. Therefore, there is an urgent need to develop a method for manufacturing high-performance metal bipolar plates for fuel cells that is both efficient and easily compatible with existing metal plate production lines.
- Patent document CN112974642A (An Electrically Assisted Forming Apparatus and Process for Fuel Cell Metal Plates) discloses an electrically assisted forming process for fuel cell metal plates. By passing an electric current through the metal plate while it is still in the mold during the stamping process, the process utilizes Joule heating and electroplasticity to reduce the plate's forming force and improve its forming accuracy and consistency. However, this electrically assisted forming process focuses on improving the manufacturing accuracy of the metal plate during single-step stamping and does not significantly enhance the metal plate's forming limit.
- Patent document CN111842611A proposes an electromagnetic-thermal composite forming method for titanium alloy bipolar plates.
- the method leverages thermal effects, electroplastic effects, and the high strain rate effect of pulsed electromagnetic force to improve the forming limit of titanium alloy plates.
- the electromagnetic forming device involved in this technology is complex, costly, and inefficient, making it unsuitable for practical production applications.
- Patent document CN116154208B proposes a heat-assisted forming process for ultra-thin titanium plates for fuel cells.
- an annealing heat treatment process between the two-step stamping process By adding an annealing heat treatment process between the two-step stamping process, the internal stress of the titanium plate after the first forming process is released and the work hardening is eliminated, thereby improving its re-deformation performance and increasing the forming limit.
- the heat treatment process in this invention is time-consuming (2-30 minutes), which affects the production efficiency of the titanium plate.
- the static recovery process of the heat treatment is often accompanied by grain growth, which limits its effect on improving the forming limit of the plate.
- the present invention aims to propose a multi-step forming production line and process for metal plates based on electrical treatment modification, which can significantly improve the forming limit and forming accuracy of metal plates, so as to solve the problems of insufficient microchannel depth, channel cracking, poor dimensional accuracy, etc. in the existing metal plate forming process without affecting production efficiency.
- the present invention provides a method for preparing fuel cell metal plates based on electrical treatment modification and a multi-step forming production line for metal plates.
- the multi-step forming production line for metal plates comprises, in sequence: a loading robot (loading equipment), a first-sequence stamping equipment, a transfer electrical treatment equipment, an electrical treatment equipment, a second-sequence stamping equipment and a unloading robot (unloading equipment).
- the present invention based on the aforementioned production line, proposes a multi-step forming production process for metal plates based on electrical treatment modification as follows:
- Electrical treatment refers to a material modification process in which direct current is passed through a metal plate to repair its internal defects and stimulate its plasticity.
- ultra-short electrical treatment can release internal stress, eliminate deformation twins and dislocation accumulation generated by ultra-thin metal plates during the pre-deformation process, and significantly promote static recrystallization, thereby improving the re-deformation performance of the pre-deformed metal plate and increasing the forming limit.
- the electrical treatment equipment can provide constant voltage direct current or pulsed direct current of arbitrary waveform, with an output voltage amplitude of 0-300V, a duty cycle of 0-100%, and a frequency of 100-4000Hz.
- the amount of electrical energy required to treat defects is also different.
- the temperature rise of the plate caused by the Joule heating effect of electrical treatment is easy to measure and can be used as a simple means to determine the level of electrical energy input and to determine the threshold of electrical treatment parameters.
- the target temperature range of electrical treatment is 500-1200°C, and the power-on time needs to be controlled within the range of 0.5-10 seconds.
- the electrical treatment time should be selected based on the production rhythm requirements, and then the electrical treatment process parameters such as output voltage, duty cycle and frequency should be determined based on the target heating temperature.
- the loading robot automatically transfers the blank to the first-order stamping equipment through the vacuum suction cup and positions the blank in the first-order forming die;
- the transfer electrical treatment equipment sucks up the preformed metal plate through the vacuum suction cup and moves it out of the first-order stamping equipment first. Then, it moves to the position of the electrical treatment fixture integrated in the transfer electrical treatment equipment, and the upper clamp of the electrical treatment fixture moves down to clamp the two ends of the preformed metal plate, and the vacuum suction cup stops working and moves up.
- the pre-deformed metal plate is clamped by the electrical treatment fixture to complete its transfer between the two-order stamping equipment, and the pre-deformed metal plate is electrically treated and modified at the same time, and it is ensured that the metal plate has completed the electrical treatment modification and cooled to room temperature before reaching the second-order stamping equipment.
- the vacuum suction cup moves down to suck up the metal plate, the electrical treatment fixture is released and retracted, and the metal plate is transferred to the second-order stamping equipment and positioned;
- the blanking robot transfers the fully formed metal plates out of the second-order stamping equipment.
- a method for preparing a fuel cell metal plate comprising:
- the first forming process uses the first stamping equipment to perform the first stamping pre-forming on the metal substrate to form a pre-formed metal plate;
- the transfer and electrical treatment process controls the transfer electrical treatment equipment to move the preformed metal electrode plate to the electrical treatment station on the transfer electrical treatment equipment for electrical treatment, and removes the electrically treated metal electrode plate after the electrical treatment is completed;
- the electrical treatment clamping area is > 500mm2 ; further, the electrical treatment clamping area is > 1500mm2 ; further, the electrical treatment clamping area is > 2000mm2 .
- a second forming step using a second stamping device to perform a second stamping forming on the electrically treated metal plate to obtain a fully formed metal plate;
- the blanking process is to remove the fully formed metal plate from the second-order stamping equipment.
- the first forming process and the second forming process further include at least one intermediate forming process to perform stamping on the metal plate, and the electrical treatment process is provided between the two forming processes.
- the transport electro-processing equipment includes an electro-processing carrying platform and a transport platform located above the electro-processing carrying platform;
- the electro-processing carrying platform includes electrode units arranged opposite to each other; the electrode units include electrode clamps that can be operated to press and open;
- the transport platform is installed above the electro-processing carrying platform via a vertical movable bracket;
- the transport platform can be operated to move up and down on the vertical movable bracket;
- the transport platform includes a rectangular frame and a suction cup assembly that can be operated to move horizontally on the rectangular frame; the suction cup assembly is used to absorb the metal substrate or the metal plate;
- the suction cup assembly has a first horizontal position (initial position) and a second horizontal position relative to the rectangular frame in a horizontal direction; the transfer platform has a first height position and a second height position above the first height position on the vertical movable bracket 5.
- the suction cup assembly is controlled to absorb the preformed metal electrode plate at the second horizontal position and the second height position, then, the electrode clamp is opened, the suction cup assembly is controlled to descend to the first height position and then move from the second horizontal position to the first horizontal position, the preformed metal electrode plate is sent between the electrode clamps, the suction cup assembly is controlled to release the preformed metal electrode plate and the electrode clamp is controlled to press the preformed metal electrode plate for electrical treatment, finally, the electrode clamp is opened and the suction cup assembly is controlled to re-absorb the electrically treated metal electrode plate and move it from the first horizontal position to the second horizontal position, and then the electrically treated metal is moved upward to the second height position.
- the robot is controlled to load the metal substrate onto the first-order stamping device, and after the first-order forming process is completed, the preformed metal plate is removed from the first-order stamping device;
- the electrically treated metal plate is transferred to the second-order stamping equipment by a robot;
- the robot is controlled to remove the fully formed metal plate from the second-order stamping equipment.
- it also includes an electrical processing parameter acquisition step, obtaining the electrical processing parameters when the maximum temperature of the preformed metal plate reaches 500-1200°C when the power is turned off at the end of the electrical processing time; the electrical processing time is 0.5-10 seconds.
- the temperature of the preformed metal plate under electrical treatment conditions is monitored by an infrared thermal imager.
- the electrical treatment uses constant voltage direct current or pulsed direct current; wherein the output voltage amplitude is 0-300V, the duty cycle is 0-100%, and the frequency is 100Hz-4000Hz.
- the maximum difference in flow channel thickness of the fully formed metal electrode plate is less than 24 ⁇ m.
- a first electrically driven guide rail is provided on the electrical processing carrier platform, and the electrode fixture includes a lower electrode whose two ends are fixedly connected to the first electrically driven guide rail and an upper electrode whose two ends are movably connected to the electrically driven guide rail, and the first electrically driven guide rail can drive the upper electrode to move up and down to open and close the electrode fixture;
- the transfer platform includes an electrically driven telescopic guide rail disposed on the lower side of the rectangular frame; the suction cup assembly is connected between the two electrically driven telescopic guide rails and is driven to switch between a first horizontal position (initial position) and a second horizontal position;
- the vertical movable bracket 5 includes two second electric drive rails vertically arranged on the electric processing bearing platform, and the rectangular frame vertically connects the two second electric drive rails and is driven to switch between the first height position and the second height position.
- a multi-step forming production line for metal plates of fuel cells implementing the above-mentioned preparation method comprises: a loading device, a first-order stamping device, a transfer and electrical processing device, a second-order stamping device, and a unloading device; wherein,
- the loading equipment is used to load the metal substrate into a first-order stamping equipment having a first-order forming mold;
- the first-order stamping equipment is used to perform first-order stamping pre-forming on the metal substrate to form a pre-formed metal plate;
- the transport electro-processing equipment is used to move the preformed metal electrode plate to the electro-processing station on the transport electro-processing equipment for electro-processing, and to take out the electro-processed metal electrode plate after the electro-processing is completed;
- the second-order stamping equipment is used to perform a second-order stamping on the metal plate after the electrical treatment to obtain a fully formed metal plate;
- the blanking equipment removes the fully formed metal plate from the second-order stamping equipment.
- the present invention has the following beneficial effects:
- the fuel cell metal plate preparation method and metal plate multi-step forming production line of the present invention incorporate an electrical treatment process between the two stamping steps. This can release the internal stress of the preformed metal plate within a very short processing time and eliminate deformation twins and dislocation accumulation, ultimately significantly improving the forming limit and forming accuracy of the metal plate.
- the fuel cell metal plate preparation method and metal plate multi-step forming production line of the present invention integrate electrical processing equipment with the transfer electrical processing equipment. This allows the preformed metal plates to be electrically processed to eliminate deformation twins and dislocation accumulation while being transferred to the next stamping process, without affecting production efficiency.
- the preparation method of the fuel cell metal plate and the metal plate multi-step forming production line of the present invention propose that the metal plate multi-step forming production line based on the electrical treatment modification effect can be obtained by simple transformation of the existing series stamping automatic production line, with low investment cost and wide application range.
- FIG1 is a diagram showing the temperature distribution and local temperature history of the target plate microchannel during electrical treatment in Example 1;
- FIG2 shows the design parameters of the runner cross-section of (a) the first forming die and (b) the second forming die in Example 1;
- FIG3 is a diagram of (a) a titanium plate formed by conventional multi-step stamping at room temperature and (b) a titanium plate formed by the new method of the present invention in Example 1;
- FIG4 is a diagram showing the flow channel thickness distribution of (a) a titanium plate formed by conventional multi-step stamping at room temperature and (b) a titanium plate formed by the new method of the present invention in Example 1;
- Figure 5 is a bar graph of the total elongation of the sample after being subjected to electrical treatment at 550°C for a long time;
- Figures 6 and 7 are bar graphs of total elongation when the samples were electrically treated at 500°C (E10.5%), 600°C (E13.5%), and 700°C (E16.8%) for 2 seconds, 3 seconds, 5 seconds, or 10 seconds, respectively.
- FIG8 is a bar graph of total elongation of samples subjected to 2-second rapid heating to different target temperatures
- FIG9 is a bar graph of the total elongation of the specimens subjected to different pre-deformations and heated to different target temperatures.
- FIG10 is a comparison of the results of two intermediate electrical treatments of the sample formed by a single die
- FIG11 is a schematic diagram of the three-dimensional structure of a transport electrical treatment device provided by one embodiment of the present invention.
- FIG12 is another view of FIG11
- FIG13 is a side view of FIG11
- FIG14 is a process diagram of a transfer electro-processing process using the transfer electro-processing equipment shown in FIG11.
- one embodiment of the present invention provides a method for preparing a fuel cell metal plate. Accordingly, to implement this method, this embodiment also provides a multi-step metal plate forming production line.
- the multi-step metal plate forming production line includes: a loading device, a first-stage stamping device, a transfer and processing device, a second-stage stamping device, and a unloading device.
- the loading equipment is used to load the metal substrate to the first-order stamping equipment with a first-order forming mold.
- the loading equipment adopts a loading robot, specifically a manipulator.
- the first-order stamping equipment is used to perform first-order stamping pre-forming on the metal substrate to form a preformed metal electrode plate.
- the transfer electrical treatment equipment is used to move the preformed metal electrode plate to the electrical treatment station on the transfer electrical treatment equipment for electrical treatment, and remove the electrically treated metal electrode plate after the electrical treatment is completed.
- the second-order stamping equipment is used to perform second-order stamping forming on the electrically treated metal electrode plate to obtain a fully formed metal electrode plate.
- the unloading equipment removes the fully formed metal electrode plate from the second-order stamping equipment.
- the unloading equipment adopts a unloading robot, specifically a manipulator.
- the loading manipulator and the unloading manipulator are different manipulators, which are arranged along the process steps of the production line.
- the loading equipment and the unloading equipment can adopt the same manipulator.
- the stamping equipment includes a stamping machine and a mold.
- the mold structure can adopt the mold disclosed in the patent publication number CN116154208A entitled "High-precision and high-corrosion-resistant titanium bipolar plates for fuel cells and their preparation method and mold assembly", and the repeated parts are not repeated here.
- the stamping machine adopts a precision press, such as a YKP-630 precision press.
- the electrical processing equipment includes a DC power supply, a copper electrode and an insulating bakelite clamp. Among them, the electrode and the insulating clamp are integrated into the transport electrical processing equipment for grabbing and transporting preformed metal plates.
- the transfer electric treatment device includes an electric treatment carrier platform 1, and a transfer platform 3 located above the electric treatment carrier platform 1; the electric treatment carrier platform 1 includes electrode units 4 arranged relatively to each other; the electrode unit 4 includes an electrode clamp that can be operated to press open.
- the transfer platform 3 is installed above the electric treatment carrier platform 1 through a vertical movable bracket 5; the transfer platform 3 can be operated to move up and down on the vertical movable bracket 5.
- the transfer platform 3 includes a rectangular frame, and a suction cup assembly 2 that can be operated to move in a horizontal direction on the rectangular frame; the suction cup assembly 2 is used to absorb the metal substrate or metal electrode 100.
- the suction cup assembly 2 has a first horizontal position and a second horizontal position relative to the rectangular frame in a horizontal direction; the transfer platform 3 has a first height position and a second height position above the first height position on the vertical movable bracket 5.
- the first horizontal position below the second height position is the initial position of the suction cup assembly 2.
- the electrical processing platform 1 is provided with a first electrically driven rail 40.
- the electrode fixture includes a lower electrode 42, fixedly connected to the first electrically driven rail 40 at both ends, and an upper electrode 41, movably connected to the first electrically driven rail 40 at both ends.
- the first electrically driven rail 40 can drive the upper electrode 41 to move up and down to open and close the electrode fixture.
- the lower electrode 42 and the upper electrode 41 are copper electrodes.
- the transfer platform 3 includes an electrically driven telescopic guide rail 31 disposed on the lower side of a rectangular frame.
- the suction cup assembly 2 is connected between two parallel electrically driven telescopic guide rails 31 and is driven to switch between a first horizontal position and a second horizontal position.
- the vertical movable bracket 5 includes two second electrically driven guide rails 51 vertically disposed on the electrical processing carrier platform 1.
- the rectangular frame vertically connects the two second electrically driven guide rails 51 and is driven to switch between a first height position and a second height position.
- the suction cup assembly 2 when the suction cup assembly 2 is in the second horizontal position and the second height position, it is used to suck or unload the metal substrate or metal plate.
- the suction cup assembly 2 When the suction cup assembly 2 is in the second horizontal position, it is used to switch between the first height position and the second height position.
- the second horizontal position is the horizontal position shown in Figure 15b.
- the suction cup assembly 2 when the suction cup assembly 2 is in the second horizontal position and the first height position, it can be moved to the first horizontal position to deliver the metal substrate or metal plate between the opened electrode clamps.
- the method for preparing a fuel cell metal plate includes the following steps:
- the first forming process uses the first stamping equipment to perform the first stamping pre-forming on the metal substrate to form a pre-formed metal plate;
- the transport and electrical treatment process controls the transport electrical treatment equipment to move the preformed metal electrode plate to the electrical treatment station on the transport electrical treatment equipment for electrical treatment, and removes the electrically treated metal electrode plate after the electrical treatment is completed; the electrical treatment clamping area is greater than 500 mm 2 ;
- a second forming step using a second stamping device to perform a second stamping forming on the electrically treated metal plate to obtain a fully formed metal plate;
- the fully formed metal plate is removed from the second-stage stamping equipment.
- the fully formed metal plate has a flow channel thickness range of less than 24 ⁇ m and a flow channel depth-to-width ratio greater than 0.79.
- the method for preparing the fuel cell metal plate is not limited to two stamping steps followed by an intermediate electrical treatment. Multiple stamping steps and multiple electrical treatment steps may be used.
- the first and second forming steps may include at least one intermediate forming step, wherein the metal plate is stamped, and the electrical treatment step is provided between the two forming steps. Through multiple electrical treatments, the metal plate can ultimately achieve a higher forming limit.
- the suction cup assembly 2 is controlled to absorb the preformed metal plate at the second horizontal position and the second height position. Then, as shown in FIG14 b to FIG14 c, the electrode clamp is opened, the suction cup assembly 2 is controlled to descend to the first height position and then move from the second horizontal position to the first horizontal position, and the preformed metal plate is fed between the electrode clamps. After the suction cup assembly 2 is controlled to release the preformed metal plate, the electrode clamp is controlled to press the preformed metal plate for electrical treatment as shown in FIG14 d, and the suction cup assembly 2 is lifted to the initial position (the second horizontal position at the second height position).
- the electrode clamp is opened and the suction cup assembly 2 is controlled to return to the position shown in FIG14 d to absorb the electrically treated metal plate and move it from the first horizontal position to the second horizontal position, and then the electrically treated metal is moved upward to the second height position.
- the method for preparing a fuel cell metal plate also includes an electrical treatment parameter acquisition step, in which the electrical treatment parameters are acquired when the maximum temperature of the preformed metal plate reaches 500-1200°C when the power is turned off after the electrical treatment time ends; the electrical treatment time is 0.5-10 seconds.
- the electrical treatment parameter acquisition step the temperature of the preformed metal plate under the electrical treatment condition is monitored by an infrared thermal imager.
- the electrical treatment adopts constant voltage direct current or pulsed direct current; wherein, the output voltage amplitude is 0-300V, the duty cycle is 0-100%, and the frequency is 100Hz-4000Hz.
- the bipolar plate has a small thickness ( ⁇ 0.2 mm) but a large electrochemical clamping area (>500 mm 2 , generally >2000 mm 2 ). This results in high contact quality between the copper electrode and the metal plate.
- a large electrochemical clamping area >500 mm 2 , generally >2000 mm 2 .
- a rubber pad is added to the surface of the upper electrode facing the lower electrode. This improves stress transfer and increases the actual contact area, resulting in more uniform conduction and more reliable clamping.
- the rubber pad is rectangular and thinner than the lower electrode.
- the rubber pad covers the lower surface of the upper electrode, while the upper surface area of the lower electrode is larger than the lower surface area of the rubber pad. The end of the metal plate is clamped between the rubber pad and the upper surface of the lower electrode.
- the preparation method of fuel cell metal plates and the metal plate multi-step forming production line provided by the embodiments of the present invention add an electrical treatment process between the two-step stamping processes, which can release the internal stress of the pre-formed metal plates in an extremely short processing time and eliminate deformation twins and dislocation accumulation, ultimately significantly improving the forming limit and forming accuracy of the metal plates.
- the embodiments of the present invention perform electrical treatment on pre-formed metal plates, especially titanium plates, which is a means of adding a step of material modification in the process of forming materials into parts. Its purpose is to improve the machinability of the material (manufacturability of parts), and then the ductility (elongation) as verified in Figures 5 to 11.
- the electrical treatment of metal plates (titanium plates) of the present invention hopes to completely eliminate defects such as dislocations and twins under the most ideal circumstances, and complete recrystallization, replacing deformed grains with new equiaxed grains, thereby maximizing the ductility of the material and achieving a higher forming limit of the metal plates.
- 5 to 10 are diagrams showing verification results obtained by the inventors in verifying the effect of electrical treatment on the metal plate forming process.
- Figure 5 shows the results of multi-step stretching and total elongation measurement of a 0.1mm thick titanium substrate produced at a steel mill (the scenario described in Example 3 below). Specifically, the titanium substrate was first stretched to 15% in the rolling direction, then subjected to electro-treatment under the different electro-treatment conditions shown in Figure 5 (5s @ 550°C, meaning the electro-treatment lasted 5 seconds, with the sheet reaching a maximum temperature of 550°C upon power failure. The maximum temperature for this set of experiments was 550°C, but the electro-treatment time varied). Finally, the titanium substrate was reloaded and stretched to fracture.
- the total elongation of the titanium substrate after the two stretches was calculated and compared with a specimen that was stretched twice without intermediate electro-treatment (marked by the green dashed line in Figure 5, where the elongation of this specimen is approximately 35.8%).
- the elongation of the specimens under each electro-treatment condition increased to varying degrees. Elongation is an important indicator of specimen ductility. A higher elongation indicates that the material can withstand greater tensile deformation before fracture, thus demonstrating the ability of electro-treatment to improve the forming limit of the titanium substrate.
- Figures 6, 7, and 8 also show the tensile test results of similar titanium plates, with only the electro-treatment parameters being varied. Again, it can be seen that the elongation of the specimens increased to varying degrees under different electro-treatment conditions.
- Figure 9 compares the total elongation after varying the pre-deformation (originally 15%, now 10%, 15%, and 20% for comparison), followed by electro-treatment for 2 seconds at 500°C, 600°C, and 700°C. Again, it can be seen that electro-treatment is equally effective for samples with varying pre-deformation, and the overall trend of the effect is consistent.
- Figure 10 shows a comparison of the results of two forming operations performed directly in the second forming die by controlling the stamping depth without using the first forming die in Figure 2.
- the improved process controls the stamping depth to about 0.25mm during the first forming process, at which time the plate still does not crack.
- the plate is then electrically treated and then placed back into the die to be fully stamped to the final depth of 0.35.
- the results shown in Figure 10 show that pure electrical treatment has a significant effect on improving the forming limit of the sheet metal. It can be seen that the specimen without electrical treatment in the traditional process completely cracked, indicating that the forming limit was completely exceeded. However, the cracking of the specimen after electrical treatment was significantly improved, which can be seen that the electrical treatment has an effect on improving the local forming limit.
- This embodiment provides a new method for improving the forming limit and cross-sectional thickness uniformity of metal plates.
- the target plate flow channel period to be formed is 1.2 mm, the draft angle is 5°, the fillet radius is 0.1 mm, and the aspect ratio is 0.79.
- the specific steps are as follows:
- the sample substrate is TA1 industrial pure titanium with a thickness of 0.1 mm and a titanium content higher than 99.5% produced by a steel plant.
- the industrial pure titanium is a titanium substrate with an ⁇ -phase structure obtained by annealing heat treatment after cold rolling.
- the electrical treatment parameters a preformed titanium plate was used, and its temperature was monitored using an infrared thermal imager during the electrical treatment. A 2-second electrical treatment time was selected, and the plate's maximum temperature reached 750°C when the power was disconnected after 2 seconds of treatment, as shown in Figure 1.
- the power supply box output voltage for the 100mm wide preformed titanium plate was 120V, with a 70% duty cycle and a pulse frequency of 300Hz.
- the ultra-thin titanium substrate obtained in S1 is transferred to the first-order stamping equipment and positioned using a loading robot.
- the first-order forming die shown in FIG. 2 a is used to perform the first-order stamping forming on the blank loaded in S3 .
- the pre-deformed titanium electrode plate obtained in S4 is sucked from the first-order stamping die by the vacuum suction cup integrated in the integrated fixture of the transfer electrical processing equipment, and is moved to the electrical processing station in the integrated fixture.
- the servo motor drives the upper chuck of the electrode to move downward to clamp the titanium electrode plate.
- the vacuum pump stops working and the suction cup moves upward.
- the pulse current calibrated in S2 is passed through the pre-deformed titanium electrode plate, and at the same time, the robotic arm of the transfer electrical processing equipment moves, driving the entire integrated fixture to move to the second-order stamping station.
- the suction cup moves down and the vacuum pump is turned on again.
- the upper chuck moves upward to release the titanium electrode plate, and the titanium electrode plate is transferred to the second-order stamping equipment by the vacuum suction cup and the positioning is completed.
- the titanium electrode plate after the electrical treatment in S5 is subjected to second-order stamping by using the second-order forming die shown in FIG. 2 b .
- the formed titanium plate is transferred out of the second-stage stamping equipment by the blanking equipment.
- the titanium plate microchannels formed by the traditional room temperature multi-step forming process and the new method proposed in the present disclosure are respectively shown.
- the new method proposed in the present invention can break through the forming limit of the titanium plate and obtain the target plate without cracking.
- the thickness distribution uniformity of the plate flow channel is evaluated by the range method, that is, 9 characteristic positions (the ridge, groove and side wall midpoint and the position of maximum fillet thinning) are selected on each flow channel line cycle to measure the thickness of the substrate. It can be found that the thickness range of the titanium plate microchannel manufactured by the traditional multi-step forming process is large (27.8 ⁇ m). The excessive thinning of the weakest fillet position (P6) ultimately causes the flow channel to crack.
- the method proposed in the present invention can promote the uniform deformation of the material during the forming process, thereby improving the uniformity of the flow channel thickness and reducing the range of the flow channel thickness to about 21.8 ⁇ m.
- This example uses the same 0.1mm thick TA1 commercially pure titanium as in Example 1.
- the target plate flow channel period is 1.18mm and the flow channel depth is 0.38mm.
- Traditional multi-step stamping can produce crack-free titanium plates, but the flow channel dimensional accuracy is poor.
- the pre-formed titanium electrode plate is first subjected to an electrical treatment.
- the electrical treatment time is selected to be 2 seconds to ensure that the maximum temperature of the flow channel area of the titanium electrode plate reaches 730°C when the power is turned off 2 seconds after the electrical treatment.
- the calibrated output voltage of the power box is 190V
- the duty cycle is 100%
- the pulse frequency is 4000Hz.
- the flow channel depth of the titanium electrode plate formed by the new method of the present invention is about 10 ⁇ m higher than that of the titanium electrode plate formed by multi-step cold stamping, and the formed flow channel cross-section is closer to the design value, which proves that the new method of the present invention can also be used as an effective means to improve the dimensional accuracy of the flow channel of the target metal electrode plate.
- the sample substrate is TA1 industrial pure titanium with a thickness of 0.1 mm and a titanium content higher than 99.5% produced by a steel plant, with the goal of increasing the elongation at break of the titanium plate.
- a titanium plate was pre-stretched to 15% elongation, then subjected to a 10-second electrical treatment, ensuring that its maximum temperature reached 550°C when the power was disconnected after the 10-second treatment. Finally, the plate was reloaded and stretched to fracture. The tensile test results showed that the titanium plate's elongation increased by approximately 23% compared to stretching under room temperature conditions.
- the sample substrate is 446 ferritic stainless steel with a thickness of 0.1 mm produced by a domestic steel plant. Based on uniaxial stretching, the feasibility of migrating the new method proposed in the present invention to ultra-thin stainless steel substrates is explored.
- a ferritic stainless steel sheet was pre-stretched to a 15% elongation, then subjected to a 2-second electrical treatment to ensure that its maximum temperature reached 1000°C when the power was disconnected after the 2-second treatment. Finally, it was reloaded and stretched to fracture. The tensile test results showed that the elongation of the ferritic stainless steel increased by approximately 32% compared to the normal temperature stretching conditions, demonstrating that the new method can improve the formability of ferritic stainless steel.
- any numerical value cited herein includes all values of the lower and upper values in increments of one unit from the lower value to the upper value, provided that there is at least a two-unit interval between any lower value and any higher value.
- a component quantity or process variable e.g., temperature, pressure, time, etc.
- values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc. are also explicitly listed in this specification.
- one unit is appropriately considered to be 0.0001, 0.001, 0.01, 0.1.
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Abstract
一种燃料电池金属极板的制备方法及金属极板多步成形生产线,燃料电池金属极板的制备方法,包括:上料工序,将金属基材上料至第一序冲压设备;金属基材的厚度小于0.2mm;第一序成形工序,利用第一序冲压设备对金属基材进行第一序冲压预成形,形成预成形金属极板;转运及电处理工序,控制转运电处理设备将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;第二序成形工序,利用第二序冲压设备对电处理后的金属极板进行第二序冲压成形,得到完全成形金属极板;下料工序,将完全成形金属极板自第二序冲压设备取下。
Description
本申请涉及燃料电池领域,尤其涉及一种基于电处理改性效应的金属极板多步成形生产线及其工艺,特别地涉及一种燃料电池金属极板的制备方法及金属极板多步成形生产线。
氢能是推动世界能源产业绿色转型的重要战略手段,质子交换膜燃料电池是氢能利用的关键技术,而大功率、长寿命和高性能是燃料电池的发展趋势。作为燃料电池的核心部件之一,双极板具有亚毫米级的微流道特征,其流道精细程度对燃料电池的发电效率、可靠性和使用寿命等具有重要影响。相比传统的石墨双极板,金属双极板兼具厚度小、成本低、机械性能卓越、导电导热性能优异等多重优势,已成为燃料电池制造技术攻关的主流趋势之一。
然而,随着燃料电池对反应气和产物水输送效率要求的不断提高,双极板需要具有更精细的流道结构以及更高的流道深宽比,超薄金属基材的成形性能瓶颈将导致其在冲压成形过程中出现提前开裂,制约了燃料电池的高性能发展。近年来,国内外针对金属双极板的成形方法进行了广泛创新。尽管诸如电磁高速成形、高温成形等实验室级的新工艺能够有效提高金属极板的成形极限,但他们均表现出生产效率低、与现有双极板产线兼容性差的问题,限制了它们在实际生产中的应用。因此,亟需开发一种既高效又能与现有金属极板生产线简单兼容的燃料电池高性能金属双极板制造方法。
专利文献CN112974642A(一种燃料电池金属极板的电辅助成形装置及工艺)中公开了一种燃料电池金属极板的电辅助成形工艺,通过在金属极板冲压成形过程中对尚在模具内的金属极板通入电流,利用焦耳热和电致塑性效应降低极板的成形力,并提高其成形精度和一致性。然而该发明的电辅助成形工艺聚焦于提高金属极板单步冲压成形的制造精度,对金属极板的成形极限无显著提升作用。
专利文献CN111842611A(一种基于多时序脉冲电流的钛合金双极板成形装置及方法)中提出了一种钛合金双极板的电磁-热复合成形方法,通过多级时序的脉冲电流放电,利用热效应、电致塑性效应以及脉冲电磁力的高应变率效应,提高了钛合金极板的成形极限。然而,该技术包含的电磁成形装置复杂、所需成本较高、生产效率较低,不适用于实际生产应用。
专利文献CN116154208B(燃料电池用高精度高耐蚀钛双极板及其制备方法、模具组件)中提出了一种燃料电池超薄钛极板的热辅助成形工艺,通过在两步冲压成形工序间添加一道退火热处理工序,释放钛极板在第一序成形后的内部应力并消除加工硬化,从而改善其再变形性能,提高成形极限。但是,该发明中的热处理工序耗时较长(2-30min),影响钛极板的生产效率。另外,热处理的静态回复过程中往往伴随着晶粒长大,限制了其对极板成形极限的提升效果。
针对上述现有技术的不足,本发明旨在提出一种基于电处理改性的金属极板多步成形生产线及其工艺,能够显著提高金属极板的成形极限和成形精度,以解决现有金属极板成形工艺存在的微流道深度不足、流道开裂、尺寸精度差等问题,并且不影响生产效率。
为实现上述目的,本发明提供一种基于电处理改性的燃料电池金属极板的制备方法及金属极板多步成形生产线,金属极板多步成形生产线依次包括:上料机器人(上料设备)、第一序冲压设备、转运电处理设备、电处理设备、第二序冲压设备和下料机器人(下料设备)。
同时本发明围绕前述的生产线,提出基于电处理改性的金属极板多步成形生产工艺如下:
S1、材料获取工序,获取0.05mm以上且0.2mm以下厚度的钛基材或铁素体不锈钢基材;
S2、电处理参数获取工序。电处理是指将直流电通入金属极板,修复其内部缺陷从而激发其塑性的材料改性过程。相比传统的炉内退火热处理,超短时的电处理即可以释放内部应力,消除超薄金属板在预变形过程中产生的变形孪晶和位错堆积,并显著促进静态再结晶,从而改善预变形金属极板的再变形性能,提高成形极限。所述电处理设备可以提供恒压直流电或任意波形的脉冲直流电,输出电压幅值为0-300V,占空比为0-100%,频率为100-4000Hz。
对于不同尺寸的极板,其处理缺陷所需要输入的电能也不相同,而电处理焦耳热效应造成的极板温升易于测量,可以作为简单的判定电能输入水平的手段,用于确定电处理参数阈值。电处理的目标温度范围为500-1200℃,通电时间需控制在0.5-10秒的范围内。实际生产中应先基于生产的节拍需求选定电处理时间,随后基于目标加热温度,确定输出电压、占空比及频率等电处理工艺参数;
S3、上料工序,由上料机器人通过真空吸盘将料片自动转运至第一序冲压设备中,并将料片在第一序成形模具中的定位;
S4、第一序成形工序,冲压机下行,通过第一序成形模具对所述金属料片进行预成形得到金属极板;
S5、转运及电处理工序,转运电处理设备通过真空吸盘吸起预成形金属极板,先将其移出第一序冲压设备。随后,移动至集成在转运电处理设备上的电处理夹具位置,电处理夹具的上夹头下移夹持在预成形金属极板两端,真空吸盘停止工作并上移。由电处理夹具夹持预变形金属极板完成其在两序冲压设备间的转运工作,同时对预变形金属极板进行电处理改性,并保证在到达第二序冲压设备前金属极板已完成电处理改性并冷却至室温。最后,真空吸盘下移吸取金属极板,电处理夹具松开并退回,金属极板被转运至第二序冲压设备中并定位;
S6、第二序成形工序,冲压机下行,通过第二序成形模具对所述电处理后的预成形金属极板进行完全冲压成形;
S7、下料工序,由下料机器人将完全成形后的金属极板转运出第二序冲压设备。
一种燃料电池金属极板的制备方法,包括:
上料工序,将金属基材上料至具有第一序成形模具的第一序冲压设备;所述金属基材的厚度小于0.2mm;
第一序成形工序,利用第一序冲压设备对所述金属基材进行第一序冲压预成形,形成预成形金属极板;
转运及电处理工序,控制转运电处理设备将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;所述电处理夹持面积>500mm
2;进一步地,所述电处理夹持面积>1500mm
2;更进一步地,所述电处理夹持面积>2000mm
2。
第二序成形工序,利用第二序冲压设备对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板;
下料工序,将所述完全成形金属极板自所述第二序冲压设备取下。
作为优选的一个方面,在所述第一序成形工序和所述第二序成形工序还包括至少一次中间序成形工序,对金属极板进行冲压成形,并且,在两个成形工序之间均设有所述电处理工序。
作为优选的一个方面,所述转运电处理设备包括电处理承载平台、以及位于电处理承载平台上方的转运平台;所述电处理承载平台包括相对设置的电极单元;所述电极单元包括可操纵地压合打开的电极夹具;所述转运平台通过竖直移动支架安装在所述电处理承载平台的上方;所述转运平台能够被操纵地沿上下移动地设置在所述竖直移动支架上;所述转运平台包括矩形框架、以及可被操纵地沿一水平方向移动地设置于所述矩形框架上的吸盘组件;所述吸盘组件用于吸取金属基材或金属极板;
所述吸盘组件相对于所述矩形框架在一水平方向上具有第一水平位置(初始位置)和第二水平位置;所述转运平台在所述竖直移动支架5上具有第一高度位置和位于所述第一高度位置上方的第二高度位置。
作为优选的一个方面,在转运及电处理工序时,控制吸盘组件在所述第二水平位置以及所述第二高度位置吸取预成形金属极板,然后,打开电极夹具,控制吸盘组件下降到第一高度位置之后从第二水平位置移动至第一水平位置,将预成形金属极板送入到电极夹具之间,控制吸盘组件释放预成形金属极板并控制电极夹具将预成形金属极板压合进行电处理,最后,打开电极夹具再控制吸盘组件重新吸取电处理后的金属极板从第一水平位置移动至第二水平位置,再将电处理后的金属向上移动至第二高度位置。
作为优选的一个方面,在上料工序时控制机械手将金属基材上料至所述第一序冲压设备,并在第一序成形工序结束后将预成形金属极板自所述第一序冲压设备上取下;
在所述转运及电处理工序结束后还通过机械手将电处理后的金属极板转移至第二序冲压设备;
在下料工序时控制机械手将所述完全成形金属极板自所述第二序冲压设备取下。
作为优选的一个方面,还包括获取电处理参数获取工序,获取预成形的金属极板在电处理时间结束断电时的最高温度达到500-1200℃时的电处理参数;电处理时间为0.5-10秒。
作为优选的一个方面,通过红外热像仪监测电处理条件下预成形金属极板的温度。
作为优选的一个方面,所述电处理采用恒压直流电或脉冲直流电;其中,输出电压幅值为0-300V,占空比为0-100%,频率为100Hz-4000Hz。
作为优选的一个方面,所述完全成形金属极板的流道厚度极差小于24μm。
作为优选的一个方面,所述电处理承载平台上设置有第一电驱导轨,所述电极夹具包括两端位置固定地连接所述第一电驱导轨的下电极以及两端可移动地连接所述电驱导轨的上电极,所述第一电驱导轨能够驱动所述上电极上下移动以打开闭合所述电极夹具;
所述转运平台包括设置于矩形框架下侧的电驱伸缩导轨;所述吸盘组件连接于两个电驱伸缩导轨之间,被驱动在第一水平位置(初始位置)和第二水平位置之间切换;
所述竖直移动支架5包括竖直设置在所述电处理承载平台上的两个第二电驱导轨,所述矩形框架垂直连接两个所述第二电驱导轨,被驱动在第一高度位置和第二高度位置之间切换。
一种实施如上所述燃料电池金属极板的制备方法的金属极板多步成形生产线,包括:上料设备、第一序冲压设备、转运电处理设备、第二序冲压设备、下料设备;其中,
所述上料设备用于将金属基材上料至具有第一序成形模具的第一序冲压设备;
所述第一序冲压设备用于对所述金属基材进行第一序冲压预成形,形成预成形金属极板;
所述转运电处理设备用于将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;
所述第二序冲压设备用于对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板;
所述下料设备将所述完全成形金属极板自所述第二序冲压设备取下。
与现有技术相比,本发明具有以下有益效果:
1. 本发明的燃料电池金属极板的制备方法及金属极板多步成形生产线在两步冲压工序间加入一道电处理工序,可以在极短的处理时间内释放预成形金属极板的内部应力,并消除变形孪晶和位错堆积,最终显著提高了金属极板的成形极限和成形精度;
2. 本发明的燃料电池金属极板的制备方法及金属极板多步成形生产线将电处理设备集成在转运电处理设备上,可在预成形金属极板转运至下一道冲压工序的同时对其进行电处理消除变形孪晶和位错堆积,不影响生产效率;
3. 本发明的燃料电池金属极板的制备方法及金属极板多步成形生产线提出基于电处理改性效应的金属极板多步成形生产线可基于现有串联冲压自动化生产线简单改造获得,投入成本低、适用范围广。
参照后文的说明和附图,详细公开了本发明的特定实施方式,指明了本发明的原理可以被采用的方式。应该理解,本发明的实施方式在范围上并不因而受到限制。
针对一种实施方式描述和/或示出的特征可以以相同或类似的方式在一个或更多个其它实施方式中使用,与其它实施方式中的特征相组合,或替代其它实施方式中的特征。
应该强调,术语“包括/包含”在本文使用时指特征、整件、步骤或组件的存在,但并不排除一个或更多个其它特征、整件、步骤或组件的存在或附加。
为了更清楚地说明本发明实施例或现有技术中的技术方案,下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域技术人员来讲,在不付出创造性劳动性的前提下,还可以根据这些附图获得其他的附图。
图1是实施例1中目标极板微流道电处理过程中的温度分布和局部温度历程;
图2是实施例1中的(a)第一序成形模具和(b)第二序成形模具流道截面设计参数;
图3是实施例1中(a)传统常温多步冲压成形的钛极板和(b)本发明新方法成形的钛极板;
图4是实施例1中(a)传统常温多步冲压成形钛极板和(b)本发明新方法成形的钛极板流道厚度分布情况;
图5是对试样进行550℃较长时间电处理下总延伸率柱形图;
图6、图7是在500℃(E10.5%)/600℃(E13.5%)/700℃(E16.8%)下对试样分别电处理2sec,3sec,5sec or 10sec下的总延伸率柱形图;
图8是对试样进行2秒快速加热至不同目标温度的总延伸率柱形图;
图9是对试样进行不同预变形量并且加热至不同目标温度下的总延伸率柱形图。
图10是通过单副模具对试样进行两次成形中间电处理结果对比图;
图11是本发明一个实施例提供的转运电处理设备立体结构示意图;
图12是图11的另一视图;
图13是图11的一侧视图;
图14是采用图11所示转运电处理设备进行转运电处理的工序视图。
为了使本技术领域的人员更好地理解本发明中的技术方案,下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例,都应当属于本发明保护的范围。
需要说明的是,当元件被称为“设置于”另一个元件,它可以直接在另一个元件上或者也可以存在居中的另一个元件。当一个元件被认为是“连接”另一个元件,它可以是直接连接到另一个元件或者可能同时存在居中另一个元件。本文所使用的术语“垂直的”、“水平的”、“左”、“右”以及类似的表述只是为了说明的目的,并不表示是唯一的实施方式。
除非另有定义,本文所使用的所有的技术和科学术语与属于本发明的技术领域的技术人员通常理解的含义相同。本文中在本发明的说明书中所使用的术语只是为了描述具体的实施方式的目的,不是旨在于限制本发明。本文所使用的术语“和/或”包括一个或多个相关的所列项目的任意的和所有的组合。
请参阅图1至图14,本发明的一个实施例中提供一种燃料电池金属极板的制备方法,相应的,为实施该制备方法,该实施例中还提供一种金属极板多步成形生产线。金属极板多步成形生产线包括:上料设备、第一序冲压设备、转运电处理设备、第二序冲压设备、下料设备。
所述上料设备用于将金属基材上料至具有第一序成形模具的第一序冲压设备。上料设备采用上料机器人,具体为机械手。所述第一序冲压设备用于对所述金属基材进行第一序冲压预成形,形成预成形金属极板。所述转运电处理设备用于将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出。所述第二序冲压设备用于对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板。所述下料设备将所述完全成形金属极板自所述第二序冲压设备取下。下料设备采用下料机器人,具体为机械手。上料机械手和下料机械手为不同机械手,其沿生产线的工序步骤设置。当然,作为可行的,上料设备和下料设备可采用同一机械手。
所述冲压设备均包括冲压机和模具。其中,模具结构可以采用专利公开号CN116154208A名称为“燃料电池用高精度高耐蚀钛双极板及其制备方法、模具组件”中所披露的模具,重复之处不再赘述。冲压机采用精压机,例如YKP-630精压机。电处理设备包括直流电源、铜电极以及绝缘电木夹具。其中,电极和绝缘夹具被集成到转运电处理设备中,用于预成形金属极板的抓取与转运。
如图11至图14所示,本实施例还提供一种转运电处理设备。该转运电处理设备包括电处理承载平台1、以及位于电处理承载平台1上方的转运平台3;所述电处理承载平台1包括相对设置的电极单元4;所述电极单元4包括可操纵地压合打开的电极夹具。所述转运平台3通过竖直移动支架5安装在所述电处理承载平台1的上方;所述转运平台3能够被操纵地沿上下移动地设置在所述竖直移动支架5上。所述转运平台3包括矩形框架、以及可被操纵地沿一水平方向移动地设置于所述矩形框架上的吸盘组件2;所述吸盘组件2用于吸取金属基材或金属极板100。
所述吸盘组件2相对于所述矩形框架在一水平方向上具有第一水平位置和第二水平位置;所述转运平台3在所述竖直移动支架5上具有第一高度位置和位于所述第一高度位置上方的第二高度位置。第二高度位置下的第一水平位置为吸盘组件2的初始位置。
具体的,所述电处理承载平台1上设置有第一电驱导轨40。所述电极夹具包括两端位置固定地连接所述第一电驱导轨40的下电极42以及两端可移动地连接所述第一电驱导轨40的上电极41,所述第一电驱导轨40能够驱动所述上电极41上下移动以打开闭合所述电极夹具。下电极42和上电极41为铜电极。
所述转运平台3包括设置于矩形框架下侧的电驱伸缩导轨31。所述吸盘组件2连接于相平行的两个电驱伸缩导轨31之间,被驱动在第一水平位置和第二水平位置之间切换。所述竖直移动支架5包括竖直设置在所述电处理承载平台1上的两个第二电驱导轨51,所述矩形框架垂直连接两个所述第二电驱导轨51,被驱动在第一高度位置和第二高度位置之间切换。
如图14中a图所示,所述吸盘组件2位于所述第二水平位置并且位于所述第二高度位置时,用于吸取或卸载金属基材或金属极板。所述吸盘组件2位于所述第二水平位置时,用于在第一高度位置和第二高度位置之间切换移动,该第二水平位置如图15中b图所示的水平位置。如图14中b图所示,所述吸盘组件2位于所述第二水平位置并且位于所述第一高度位置时,可移动至第一水平位置将金属基材或金属极板送入到打开的电极夹具之间。
在本实施例中,燃料电池金属极板的制备方法包括以下工序步骤:
上料工序,将厚度在0.05mm以上且0.2mm以下的金属基材上料至具有第一序成形模具的第一序冲压设备;
第一序成形工序,利用第一序冲压设备对所述金属基材进行第一序冲压预成形,形成预成形金属极板;
转运及电处理工序,控制转运电处理设备将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;所述电处理夹持面积>500mm
2;
第二序成形工序,利用第二序冲压设备对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板;
下料工序,将所述完全成形金属极板自所述第二序冲压设备取下。所述完全成形金属极板的流道厚度极差小于24μm,流道深宽比大于0.79。
在其他实施例中,该燃料电池金属极板的制备方法并不局限于两次冲压成形一次中间电处理,其可以多步冲压工序以及多次电处理工序,如此,在所述第一序成形工序和所述第二序成形工序还包括至少一次中间序成形工序,对金属极板进行冲压成形,并且,在两个成形工序之间均设有所述电处理工序。通过多次电处理,金属极板可以最终实现更高的成形极限。
如图14所示,在转运及电处理工序时,首先,如图14中a图所示,控制吸盘组件2在所述第二水平位置以及所述第二高度位置吸取预成形金属极板,然后,如图14中b图至c图所示,打开电极夹具,控制吸盘组件2下降到第一高度位置之后从第二水平位置移动至第一水平位置,将预成形金属极板送入到电极夹具之间,控制吸盘组件2释放预成形金属极板之后如图14中d图所示控制电极夹具将预成形金属极板压合进行电处理,抬升吸盘组件2至初始位置(第二高度位置的第二水平位置)。最后,打开电极夹具再控制吸盘组件2重新回到d图所示位置吸取电处理后的金属极板从第一水平位置移动至第二水平位置,再将电处理后的金属向上移动至第二高度位置。
在上料工序时控制机械手将金属基材上料至所述第一序冲压设备,并在第一序成形工序结束后将预成形金属极板自所述第一序冲压设备上取下。在所述转运及电处理工序结束后还通过机械手将电处理后的金属极板转移至第二序冲压设备。在下料工序时控制机械手将所述完全成形金属极板自所述第二序冲压设备取下。
该燃料电池金属极板的制备方法还包括获取电处理参数获取工序,获取预成形的金属极板在电处理时间结束断电时的最高温度达到500-1200℃时的电处理参数;电处理时间为0.5-10秒。在电处理参数获取工序中,通过红外热像仪监测电处理条件下预成形金属极板的温度,
所述电处理采用恒压直流电或脉冲直流电;其中,输出电压幅值为0-300V,占空比为0-100%,频率为100Hz-4000Hz。
在本实施例中,考虑到双极板厚度小(<0.2mm),但电处理夹持面积大(>500mm
2,一般>2000mm
2),如此对于铜电极与金属极板间的接触质量高,但是由于是刚性表面的接触,上下电极加工过程中的表面平面度误差、上下电极与电极夹具间的装配误差、以及上电极向下运动过程中的运动误差都可能导致双极板的被夹持面在电极合拢状态下的应力分布不均匀,这就可能造成预成形极板在电处理过程中出现问题:由于局部接触电阻差异导致的电流密度不均匀,甚至在接触表面发生电蚀损伤;夹持段局部弯曲变形;夹紧力无法均匀有效施加而发生滑动等问题。
为解决此类问题的发生,在上电极朝向下电极的表面增设橡胶垫,从而改善应力传递并增加实际接触面积,使导电更均匀、夹持更可靠。橡胶垫为矩形橡胶垫,橡胶垫的厚度小于下电极的厚度。上下两个电极中,橡胶垫将上电极的下表面覆盖,下电极的上表面面积大于橡胶垫的下表面面积。金属极板的端部被夹持在橡胶垫和下电极的上表面之间。
本发明实施例所提供的燃料电池金属极板的制备方法及金属极板多步成形生产线在两步冲压工序间加入一道电处理工序,可以在极短的处理时间内释放预成形金属极板的内部应力,并消除变形孪晶和位错堆积,最终能够显著提高金属极板的成形极限和成形精度。
本发明的实施例对于预成形后的金属极板尤其钛极板进行电处理,是在材料到零件的成形过程中添加一步材料改性的手段,其目的在于提高材料的可加工性(零件的可制造性),进而如图5到图11所验证的延展性(伸长率),本发明对于金属极板(钛极板)的电处理则希望在最理想的情况下完全消除位错、孪晶等缺陷,并完成再结晶,由全新的等轴态晶粒代替变形晶粒,最大程度地提高材料的延展性,借此实现更高的金属极板的成形极限。
图5至图10为发明人验证电处理在金属极板成形过程中的作用所得到的验证结果图。
其中,图5是对某钢厂生产的0.1mm厚的钛基材进行多步拉伸并测量总延伸率的结果(即下述实施例3中描述的场景)。具体的,是将钛基材先沿轧制方向拉伸至15%,随后在图5所示的不同电处理条件下进行电处理(5s@550℃即电处理5秒,断电时的板料最高温度达到550℃。这一组实验的最高温度都为550℃,但电处理时间变化),最后再次加载拉伸至断裂。计算钛基材两次拉伸的总延伸率,与同样两次拉伸但中间不进行电处理的试样进行对比(即图5中绿色虚线标注的位置,该试样的延伸率约为35.8%),各电处理条件下的试样延伸率均有不同程度的提高。延伸率作为评估试样延展性的重要指标,延伸率越高说明材料在断裂前能够承受更大程度的拉伸变形,从而证明了电处理提高钛基材成形极限的能力。
图6,图7,图8同样为类似的钛板的拉伸实验结果,仅改变了电处理的参数。同样可以看出在不同电处理条件下的试样延伸率均有不同程度的提高。图9则是改变了不同的预变形量(原本是只有15%,现在是10%、15%、20%放在一起对比),然后再分别经历2sec@500℃、600℃和700℃电处理后的总延伸率对比。同样可以看出,对不同预变形量的样品,电处理一样有效,且效果的总体趋势一样。
图10是不使用图2中的第一序成形模具,而直接在第二序成形模具中,通过控制冲压深度进行的两次成形进行的对比结果图。相比于传统单纯的多步冲压成形(图10上方图片),改善后的工艺是(图10下方图片)在第一次成形时候控制冲压深度到约0.25mm,此时极板仍不出现开裂,之后再将该极板进行电处理后再放回模具中完全冲压至0.35的最终深度。从图10显示的结果可以看出纯粹的电处理对于板料的成形极限存在较大的提升效果,可以看到传统工艺不进行电处理的试样完全开裂,进而说明完全超出成形极限,而电处理后的试样,开裂情况有明显改善,可以说明电处理对局部成形极限的提升效果。
下面通过几个具体的实施例来进一步对本发明展开说明,以便更好地理解本发明。
实施例1
本实施例提供一种能够提高金属极板成形极限和截面厚度分布均匀性的新方法,拟成形的目标极板流道周期为1.2mm,拔模角度为5°,圆角半径为0.1mm,深宽比为0.79,其具体步骤如下:
S1、原材料选择
本实施例中试样基材选取某钢厂生产的厚度为0.1mm的钛元素含量高于99.5%的TA1工业纯钛,所述工业纯钛为冷轧后进行退火热处理获得组织为α相的钛基材。
S2、电处理参数获取
为获取电处理参数,利用一片已经进行过预成形的钛极板,通过红外热像仪监测电处理条件下预成形钛极板的温度。选定电处理时间为2秒,并保证钛极板在电处理2秒钟后断电时的最高温度达到750℃,如图1所示。对于该实施例中宽度100mm的预成形钛极板,获得的电源箱输出电压为120V,占空比为70%,脉冲频率为300Hz。
S3、上料
利用上料机器人将S1中获取的超薄钛基材转运至第一序冲压设备并定位。
S4、第一序成形
利用如图2a所示的第一序成形模具对S3中上料后的料片进行第一序冲压成形。
S5、转运及电处理
利用集成在转运电处理设备一体化夹具上的真空吸盘从第一序冲压模具中吸取S4中获得的预变形钛极板,并将其移动至一体化夹具中的电处理工位。识别到预变形钛极板到达指定位置后,伺服电机驱动电极上夹头向下运动,夹紧钛极板。随后,真空泵暂停工作,吸盘上移。向预变形钛极板通入S2中标定的脉冲电流,同时转运电处理设备的机械臂运动,带动整个一体化夹具向第二序冲压工位移动。电处理结束后,吸盘下移并重新打开真空泵,上夹头向上运动松开钛极板,由真空吸盘转运钛极板至第二序冲压设备并完成定位。
S6、第二序成形
利用如图2b所示的第二序成形模具对S5中电处理后的钛极板进行第二序冲压成形。
S7、下料
由下料设备将成形后的钛极板转运出第二序冲压设备。
如图3所示分别是采用传统常温多步成形工艺和本公开中提出的新方法成形的钛极板微流道,采用本发明提出的新方法可突破钛极板的成形极限,获得不开裂的目标极板。如图4所示通过极差法评价极板流道的厚度分布均匀性,即在每个流道型线周期上选取9个特征位置(分别为脊、槽和侧壁中点以及圆角最大减薄位置)测量其基材厚度,可以发现传统多步成形工艺制造的钛极板微流道的厚度极差大(27.8μm),其最薄弱的圆角位置(P6)的过大减薄最终造成了流道的开裂。而本发明提出的方法可以促进材料在成形过程中的均匀变形,从而提高流道厚度均匀性,将流道厚度极差减小到约21.8μm。
实施例2
本实施例使用与实施例1相同的厚度为0.1mm的TA1工业纯钛,拟成形的目标极板流道周期为1.18mm,流道深度为0.38mm。采用传统多步冲压成形可以制造出不开裂的钛极板,但流道尺寸精度差。
采用本发明提供的新方法,对预成形后的钛极板先进行一次电处理。选定电处理时间为2秒,保证钛极板在电处理2秒钟后断电时的流道区最高温度达到730℃。此时标定获得的电源箱输出电压为190V, 占空比为100%,脉冲频率为4000Hz。采用本发明新方法成形的钛极板流道深度相比多步冷冲压成形的钛极板高约10μm,成形流道截面更接近设计值,证明了本发明新方法也可以作为提高目标金属极板流道尺寸精度的有效手段。
实施例3
本实施例中试样基材选取某钢厂生产的厚度为0.1mm的钛元素含量高于99.5%的TA1工业纯钛,目标在于提高钛板的断裂延伸率。
采用本发明提供的新方法,将钛板预拉伸至15%延伸率,随后进行10秒电处理,保证其在电处理10秒后断电时的最高温度达到550℃。最后再次加载拉伸至断裂。拉伸实验结果表明,钛板的延伸率相比常温拉伸条件下提高约23%。
实施例4
本实施例中试样基材选取国内某钢厂生产的厚度为0.1mm的446铁素体不锈钢,基于单向拉伸,探索了本发明提出的新方法迁移应用到超薄不锈钢基材的可行性。
采用本发明提供的新方法,将铁素体不锈钢板预拉伸至15%延伸率,随后进行2秒电处理,保证其在电处理2秒后断电时的最高温度达到1000℃,最后再次加载拉伸至断裂。拉伸实验结果表明,铁素体不锈钢的延伸率相比常温拉伸条件下提高约32%,证明本发明新方法可以提高铁素体不锈钢的成形性。
本文引用的任何数值都包括从下限值到上限值之间以一个单位递增的下值和上值的所有值,在任何下值和任何更高值之间存在至少两个单位的间隔即可。举例来说,如果阐述了一个部件的数量或过程变量(例如温度、压力、时间等)的值是从1到90,优选从20到80,更优选从30到70,则目的是为了说明该说明书中也明确地列举了诸如15到85、22到68、43到51、30到32等值。对于小于1的值,适当地认为一个单位是0.0001、0.001、0.01、0.1。这些仅仅是想要明确表达的示例,可以认为在最低值和最高值之间列举的数值的所有可能组合都是以类似方式在该说明书明确地阐述了的。
除非另有说明,所有范围都包括端点以及端点之间的所有数字。与范围一起使用的“大约”或“近似”适合于该范围的两个端点。因而,“大约20到30”旨在覆盖“大约20到大约30”,至少包括指明的端点。
应该理解,以上描述是为了进行图示说明而不是为了进行限制。通过阅读上述描述,在所提供的示例之外的许多实施方式和许多应用对本领域技术人员来说都将是显而易见的。因此,本教导的范围不应该参照上述描述来确定,而是应该参照所附权利要求以及这些权利要求所拥有的等价物的全部范围来确定。出于全面之目的,所有文章和参考包括专利申请和公告的公开都通过参考结合在本文中。在前述权利要求中省略这里公开的主题的任何方面并不是为了放弃该主体内容,也不应该认为发明人没有将该主题考虑为所公开的发明主题的一部分。
Claims (10)
- 一种燃料电池金属极板的制备方法,包括:上料工序,将厚度在0.05mm以上且0.2mm以下的金属基材上料至具有第一序成形模具的第一序冲压设备;第一序成形工序,利用第一序冲压设备对所述金属基材进行第一序冲压预成形,形成预成形金属极板;转运及电处理工序,控制转运电处理设备将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;所述电处理夹持面积>500mm 2;第二序成形工序,利用第二序冲压设备对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板;下料工序,将所述完全成形金属极板自所述第二序冲压设备取下。
- 如权利要求1所述的燃料电池金属极板的制备方法,其中,在所述第一序成形工序和所述第二序成形工序还包括至少一次中间序成形工序,对金属极板进行冲压成形,并且,在两个成形工序之间均设有所述电处理工序。
- 如权利要求1所述的燃料电池金属极板的制备方法,其中,所述转运电处理设备包括电处理承载平台、以及位于电处理承载平台上方的转运平台;所述电处理承载平台包括相对设置的电极单元;所述电极单元包括可操纵地压合打开的电极夹具;所述转运平台通过竖直移动支架安装在所述电处理承载平台的上方;所述转运平台能够被操纵地沿上下移动地设置在所述竖直移动支架上;所述转运平台包括矩形框架、以及可被操纵地沿一水平方向移动地设置于所述矩形框架上的吸盘组件;所述吸盘组件用于吸取金属基材或金属极板;所述吸盘组件相对于所述矩形框架在一水平方向上具有第一水平位置和第二水平位置;所述转运平台在所述竖直移动支架上具有第一高度位置和位于所述第一高度位置上方的第二高度位置。
- 如权利要求3所述的燃料电池金属极板的制备方法,其中,在转运及电处理工序时,控制吸盘组件在所述第二水平位置以及所述第二高度位置吸取预成形金属极板,然后,打开电极夹具,控制吸盘组件下降到第一高度位置之后从第二水平位置移动至第一水平位置,将预成形金属极板送入到电极夹具之间,控制吸盘组件释放预成形金属极板并控制电极夹具将预成形金属极板压合进行电处理,最后,打开电极夹具再控制吸盘组件重新吸取电处理后的金属极板从第一水平位置移动至第二水平位置,再将电处理后的金属向上移动至第二高度位置。
- 如权利要求3所述的燃料电池金属极板的制备方法,其中,在上料工序时控制机械手将金属基材上料至所述第一序冲压设备,并在第一序成形工序结束后将预成形金属极板自所述第一序冲压设备上取下;在所述转运及电处理工序结束后还通过机械手将电处理后的金属极板转移至第二序冲压设备;在下料工序时控制机械手将所述完全成形金属极板自所述第二序冲压设备取下。
- 如权利要求3所述的燃料电池金属极板的制备方法,其中,还包括获取电处理参数获取工序,获取预成形的金属极板在电处理时间结束断电时的最高温度达到500-1200℃时的电处理参数;电处理时间为0.5-10秒。
- 如权利要求1所述的燃料电池金属极板的制备方法,其中,通过红外热像仪监测电处理条件下预成形金属极板的温度。
- 如权利要求1所述的燃料电池金属极板的制备方法,其中,所述电处理采用恒压直流电或脉冲直流电;其中,输出电压幅值为0-300V,占空比为0-100%,频率为100Hz-4000Hz。
- 如权利要求3所述的燃料电池金属极板的制备方法,其中,所述电处理承载平台上设置有第一电驱导轨,所述电极夹具包括两端位置固定地连接所述第一电驱导轨的下电极以及两端可移动地连接所述电驱导轨的上电极,所述第一电驱导轨能够驱动所述上电极上下移动以打开闭合所述电极夹具;所述转运平台包括设置于矩形框架下侧的电驱伸缩导轨;所述吸盘组件连接于两个电驱伸缩导轨之间,被驱动在第一水平位置和第二水平位置之间切换;所述竖直移动支架包括竖直设置在所述电处理承载平台上的两个第二电驱导轨,所述矩形框架垂直连接两个所述第二电驱导轨,被驱动在第一高度位置和第二高度位置之间切换。
- 一种实施如权利要求1所述燃料电池金属极板的制备方法的金属极板多步成形生产线,其中,包括:上料设备、第一序冲压设备、转运电处理设备、第二序冲压设备、下料设备;其中,所述上料设备用于将金属基材上料至具有第一序成形模具的第一序冲压设备;所述第一序冲压设备用于对所述金属基材进行第一序冲压预成形,形成预成形金属极板;所述转运电处理设备用于将预成形金属极板移动至转运电处理设备上的电处理工位进行电处理,在电处理结束后将电处理后的金属极板取出;所述第二序冲压设备用于对对所述电处理后的金属极板进行第二序冲压成形得到完全成形金属极板;所述下料设备将所述完全成形金属极板自所述第二序冲压设备取下。
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