according to a recent report on bcbusiness.ca, british columbia-based terrella energy systems is bringing its high-volume roll embossing graphite manufacturing process to the growing energy and thermal management markets.

terrella energy systems is bringing its graphite manufacturing process to the
thermal management industry. (wikimedia commons)

terrella energy systems was founded in 2012 by john kenna, who took his knowledge of graphite from his work at ballard power systems on hydrogen fuel cells. he was tasked with creating corrosion-resistant graphite plates for batteries and energy storage, but the process was slow.

over the past four years, kenna and his team at terrella energy systems have been perfecting a roll-embossing technology to produce graphite-embossed bipolar plates in bulk. according to the article, they are creating plates every three seconds, compared to every 20 seconds with a stamped process.

according to the terrella energy website, “starting with your cad geometry and basic requirements, we will convert your plate configuration to a roll pattern that is applied to a roll die. this roll die will be used to compress and create graphite components at a high volume. we have the technique and skills to convert your flow field plate geometry into embossing dies for either flat or roll embossing, depending on your special requirements.”

it added, “a tool steel drum insert, or roll die, is fabricated to this model and your pattern is machined onto the complex curve die surface. embossing dies, once completed, are installed onto our assembly processing station. the graphite material is embossed using your fabricated roll-die, with full attention paid to materials, process measures, and production requirements, manufacturing your component.”

although terrella energy only has three full-time employees at the moment, the bcbusiness.ca article noted, “kenna is leveraging a research partnership through sfu’s laboratory for alternative energy conversion. headed by engineering professor majid bahrami, the lab secured $700,000 in natural sciences and engineering research council of canada (nserc) funding and united terrella with burnaby-based telecom and electronics manufacturer alpha technologies ltd. and vancouver’s westport innovations, a specialist in natural-gas engines and vehicles, to explore the estimated us$40 billion market for graphite thermal management products.”

compare the terrella energy roll-embossing process to others at http://www.terrellaenergy.com/process.