Fuel Cell Separator Draft Control for Conductivity
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Solution Overview
Problem
Carbon-material based fuel cell separators face a challenge in achieving improved conductivity while maintaining strength, as the resin used for strength often reduces conductivity.
Innovation Solution
A manufacturing method involving a material sheet with a fiber sheet, carbon particles, and resin, where the material is pressed into a recess-projection shape with a higher draft for the top portion than the shift portion, causing resin to flow to the shift portion and increasing carbon particle concentration in the top portion, thereby enhancing conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin is added to carbon-material based separator to secure strength, then strength is improved, but conductivity deteriorates
Solution Approach 1:
The patent applies local quality by creating different resin content ratios in different portions of the separator. The top portion (gas circulation passage) has a lower resin content ratio to maintain high conductivity for electrical contact, while the shift portion has a higher resin content ratio to provide sufficient strength and structural support. This spatial differentiation of material composition resolves the contradiction between overall strength requirements and local conductivity needs.
2Reliability
If metallic material is used for separator, then conductivity is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent uses composite materials by combining carbon particles (providing conductivity and corrosion resistance) with resin (providing strength and structural integrity). This carbon-resin composite structure achieves both high conductivity through the carbon network and excellent corrosion resistance, while the resin matrix provides the necessary mechanical strength. This composite approach eliminates the corrosion problem of metallic separators while maintaining their conductivity advantage.
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
This method effectively increases the conductivity of the fuel cell separator while maintaining strength by adjusting the content ratio of carbon particles and resin in specific portions, improving electrical contact between adjacent separators.
Implementation Method 1
the material sheet is pressed into a recess-projection shape by which a gas circulation passage is to be formed, and forming a top portion and a shift portion. In the pressing of the material sheet, the material sheet is pressed such that a draft of the top portion is higher than a draft of the shift portion
Data Source
AI summary
This disclosure provides a manufacturing method for manufacturing a fuel cell separator. The manufacturing method includes: providing a material sheet including a fiber sheet, carbon particles, and a resin, the carbon particles and the resin being applied to the fiber sheet; and pressing the material sheet into a recess-projection shape by which a gas circulation passage is to be formed, and forming a top portion and a shift portion. In the pressing of the material sheet, the material sheet is pressed such that a draft of the top portion is higher than a draft of the shift portion.