Fuel Cell Metal Separator Gold Coating Adhesion

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Solution Overview

Problem

Metal separators in fuel cells with gold plating experience peeling issues, leading to reduced service life and compromised conductivity, corrosion resistance, and abrasion resistance.

Innovation Solution

A fuel cell metal separator with wave-like shape and noble metal coating layers, including main and reticulate portions formed through surface roughening and inkjet deposition, providing a strong and reliable coating that suppresses peeling and maintains conductivity and resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrolytic plating is used to form gold coating on convex portions, then conductivity and corrosion resistance are improved, but the gold coating peels off easily and service life is reduced

Engineering Contradiction:

Improvecoating durabilityVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

A roughening treatment is performed on the convex portions before applying the noble metal coating. This preliminary action creates a rough surface that enhances mechanical interlocking and adhesion between the base metal and the coating layer, preventing peeling and extending service life.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional electrolytic plating process is replaced with an inkjet-based deposition method. This substitution allows for precise control of coating application, forming a reticulate pattern that maintains electrical conductivity while improving adhesion and reducing material usage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If continuous gold plating is applied on convex portions, then corrosion resistance is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of applying continuous gold plating, the invention applies noble metal coating only in specific reticulate patterns where needed for corrosion protection and conductivity. This local quality approach reduces manufacturing complexity and material cost while maintaining essential protective functions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses partial action by applying noble metal coating only in reticulate portions rather than complete coverage. This partial coating is sufficient to provide the necessary corrosion resistance and electrical conductivity without the complexity and cost of full continuous plating.

Inventive Principle:

Principle #16Partial or excessive action

3Reliability

If complete surface coverage with noble metal is applied, then corrosion resistance is improved, but manufacturing cost and material usage increase

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidnoble metal consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention applies noble metal coating selectively in reticulate patterns only where required for corrosion protection and electrical contact, rather than covering the entire surface. This significantly reduces noble metal consumption while maintaining adequate corrosion resistance at critical locations.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Partial coating coverage is used instead of complete surface coverage. The reticulate pattern provides sufficient protection and conductivity with reduced material usage, achieving the necessary performance without excessive noble metal consumption.

Inventive Principle:

Principle #16Partial or excessive action

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 solution effectively prevents peeling of noble metals while ensuring good conductivity, corrosion resistance, and abrasion resistance, enhancing the durability and performance of fuel cell metal separators.

Implementation Method 1

ejecting noble metal particles from an inkjet device to form noble metal coating layers on the convex portions

Methodology Applied

Scientific EffectInkjet deposition:

Implementation Method 2

performing a surface roughening treatment on the convex portions

Methodology Applied

Scientific EffectSurface roughening:

Data Source

PatentUS8980501B2Fuel cell metal separator and noble metal coating method therefor

Publication Date: 2015.03.17 HONDA MOTOR CO LTD

AI summary

A first metal separator and an electrolyte electrode assembly are stacked in a fuel cell. The first metal separator comprises a convex portion that abuts against the electrolyte electrode assembly, and a concave portion forming an oxygen-containing gas flow channel between the electrolyte electrode assembly and the concave portion. A gold coating layer is formed on the convex portion. The gold coating layer includes a main gold coating portion and a reticulate gold coating portion that extends around the main gold coating portion.