Hollow Embossing Rolling
High-throughput forming of bipolar plates
Up to 120 half-plates per minute - Deep-drawing is an efficient and resource-saving forming process that offers significant advantages over conventional methods, particularly when manufacturing complex component geometries. The BPPflexROLL and flexROLLmax set new standards for scalable production of bipolar plates.
Using continuous processes to improve cost-effectiveness
Using this newly developed technology, the structure of the bipolar plate is formed by a pair of rollers through which the wafer-thin metal strip, clamped between them, passes continuously. One forming roller acts as a punch, while the other acts as a die. This continuous rolling process enables high-volume production.
Since the rollers used to form the flow channels have virtually only linear contact with the workpiece, the process forces can be reduced by a factor of 10 on average compared to conventional embossing, thanks to the step-by-step forming process. This results in smaller, more cost-effective equipment. Another advantage of the system lies in its flexibility: The number of roller sets required can be individually adjusted depending on the bipolar plate geometry.
Forming technology for high-throughput production
Production rates of >100 BPHP/min
The BPPflexROLL is a flexible, modular forming system designed for high-throughput production, capable of production rates of up to >100 BPHP/min. It can be adapted to different bipolar plate geometries and production requirements. Its central component is a robust rolling stand that ensures the continuous transport of the metal strip through multiple forming stages.
The system design allows for the flexible combination and expansion of roller sets, making the BPPflexROLL suitable for both development tasks and near-production applications. Thanks to its compact and scalable design, the system can be easily integrated into existing production environments and expanded in stages.
The flexROLLmax is a scaled-up version designed specifically for larger component geometries and thicker materials (e.g., electrolyzer plates).
For compact and delicate components
High production rates
up to 120 BPHP/min
Max. belt speed
46 m/min (D245)
Max. production width
250 mm
Max. torque
1.800 Nm
Sheet thickness
0,05 –0,1 mm
Max. rolling force
75 kN
Roll diameter
240 –310 mm
For larger components and thicker materials
High production rates
> 60 BPHP/min
Max. belt speed
25 m/min (D400 mm)
Max. production width
500 mm
Max. torque
4.900 Nm
Sheet thickness
0,1 – 0,5 mm
Max. rolling force
600 kN
Walzendurchmesse
320 – 400 mm
Get started on your technology project today!
Contact us for a no-obligation consultation about your development ideas. We’ll help you develop the technologies and processes of the future. Together, we’ll find the best solution for your challenges.
Contact
- +49 371 5397-1725
- sebastian.melzer@iwu.fraunhofer.de