CNT-Coated Fuel Cell Separator for Strength and Gas Barrier
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Solution Overview
Problem
Fuel cell separators require higher strength, electrical conductivity, and gas barrier properties, with existing carbon material group separators being inadequate in mechanical strength and electrical conductivity, and metal material group separators facing issues with corrosion and high specific gravity.
Innovation Solution
A fuel cell separator comprising a plate with graphite and resin, coated with a surface layer film containing carbon nanotubes and polyphenylene sulfide, and optionally an intermediate layer film, to enhance strength, conductivity, and gas barrier properties, manufactured using a method involving multiple layer films and shaping processes to form grooves as flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon material group separators are used, then corrosion resistance is improved and specific gravity is reduced, but mechanical strength and electrical conductivity are insufficient
Solution Approach 1:
The invention uses a composite structure consisting of a carbon material base layer (providing corrosion resistance and low density) combined with a metal plate layer (providing mechanical strength and electrical conductivity). This composite approach allows both material groups to contribute their advantageous properties to the final separator product.
2Strength
If metal material group separators are used, then mechanical strength and processability are improved, but specific gravity increases and corrosion resistance decreases
Solution Approach 1:
The invention uses a composite structure consisting of a carbon material base layer (providing corrosion resistance and low density) combined with a metal plate layer (providing mechanical strength and electrical conductivity). This composite approach allows both material groups to contribute their advantageous properties to the final separator product.
3Reliability
If metal material group separators are coated with precious metal plating or sputtering, then corrosion resistance is improved, but costs increase
Solution Approach 1:
The invention replaces expensive precious metal coatings with a more cost-effective composite structure using abundant carbon materials and standard metals, achieving comparable or superior corrosion resistance without the high material costs associated with precious metal plating or sputtering processes.
4Strength
If graphite particles are dispersed in thermoplastic resin, then mechanical strength is improved to a certain extent, but electrical conductivity and gas barrier property remain insufficient
Solution Approach 1:
The invention uses a composite structure consisting of a carbon material base layer (providing corrosion resistance and low density) combined with a metal plate layer (providing mechanical strength and electrical conductivity). This composite approach allows both material groups to contribute their advantageous properties to the final separator product.
Data Source
AI summary
An object is to provide a fuel cell separator and a manufacturing method thereof realizing excellent strength, electrical conductivity, and gas barrier property. The present invention is related to a fuel cell separator and a manufacturing method thereof, the fuel cell separator comprising: a plate that contains graphite and resin and comprises, on surfaces thereof, grooves, serving as flow paths; and surface layer films, that cover the surfaces on both sides of the plate in a thickness direction thereof, including the grooves, and the surfaces of the plate other than the grooves, wherein the surface layer films, contain resin and carbon nanotubes.