Fuel Cell Interconnects with Nickel-Tin Coating
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Solution Overview
Problem
Conventional methods for manufacturing fuel cell interconnects are labor-intensive and limited in geometry and size, with high contact resistance and low corrosion resistance, making them unsuitable for mass production and miniaturization for micro fuel cell applications.
Innovation Solution
A method involving electrochemical etching of conductive sheets with micro fluid flow channels and a corrosion-resistant coating of multiple layers of nickel and tin, applied via electroplating, to create scalable and durable interconnects with high electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining methods are used to fabricate interconnects, then the flow channels can be created in electrically conducting materials, but the manufacturing process becomes labor-intensive and limited in geometry and size
Solution Approach 1:
The patent replaces conventional mechanical machining methods with electrochemical etching to fabricate flow channels in interconnect plates. This substitution enables mass production capability and overcomes geometric limitations while maintaining the ability to create precise channels in electrically conducting materials such as stainless steel and graphite.
2Reliability
If conventional interconnect materials are used, then electrical conductivity is achieved, but corrosion resistance is insufficient
Solution Approach 1:
The patent employs composite material structures by combining electrochemically etched interconnect plates with selective corrosion-resistant coatings. This approach maintains the electrical conductivity and structural integrity of the base material while adding corrosion protection, thereby reducing both corrosion-related failures and contact resistance issues.
3Volume of moving object
If miniaturization is implemented for micro fuel cells, then system size is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies electrochemical etching to enable precise miniaturization of fuel cell components. This method allows for the fabrication of small-scale interconnect plates with complex micro-scale flow channel geometries that would be difficult to achieve through conventional mechanical machining, thereby facilitating micro fuel cell development without proportionally increasing manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of interconnects with small channel dimensions and high corrosion resistance, achieving power densities of up to 135 mW/cm² and operational lifetimes exceeding 4500 hours, suitable for micro fuel cells and other electrochemical devices.
Implementation Method 1
etching predetermined fluid flow channels in a first conductive sheet
Implementation Method 2
coating the first conductive sheet with a corrosion resistant layer
Data Source
AI summary
A method of construction of an electrochemical interconnect plate, the method comprising the steps of: (a) etching predetermined fluid flow channels in a first conductive sheet; and (b) coating the first conductive sheet with a corrosion resistant layer of nickel and tin.