Fuel Cell Separator Integrally Bonded Composite Layers
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Solution Overview
Problem
Conventional metal separators for fuel cells experience high contact resistance due to the contact surface between two metal plates, which reduces the efficiency of the fuel cell, and are prone to corrosion in humid environments.
Innovation Solution
The solution involves growing carbon nanotubes on both sides of the upper and lower metal plates and forming composite material layers with a polymer composite material, which are integrally bonded before drying to minimize contact resistance, using a conductive polymer like polyamide-imide (PAI) as a filler for strong adhesion and reduced resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polymer composite material is coated on both metal plates to prevent corrosion, then corrosion resistance is improved, but contact resistance increases due to the formation of separate coating layers
Solution Approach 1:
The patent merges the separate coating layers on the upper and lower metal plates by integrally bonding them before drying, forming a single continuous intermediate composite material layer. This eliminates the contact surface between separate layers, reducing contact resistance while maintaining corrosion protection through the unified coating structure.
Solution Approach 2:
The patent applies the polymer composite material coating to both metal plates before stacking and bonding. By performing the coating operation in advance while the plates are separate, the coating layers are formed and then integrally bonded together, creating a continuous protective layer that eliminates contact resistance at the interface.
2Ease of manufacture
If conventional coating methods are used with separate coating layers on each plate, then manufacturing process is simple, but contact resistance is high due to the contact surface between layers
Solution Approach 1:
The patent combines the previously separate coating layers into a single intermediate composite material layer by integrally bonding them before drying. This merging eliminates the contact surface between layers, reducing contact resistance while maintaining the simplicity of the coating application process.
Solution Approach 2:
The patent changes the state of the coating layers from separate dried layers to a bonded wet state before drying. By integrally bonding the coating layers while they are still in a pliable, undried state, the patent creates a continuous layer that eliminates contact resistance, then completes the drying process to finalize the structure.
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 approach significantly reduces contact resistance between the metal plates, enhancing the efficiency of the fuel cell by eliminating the contact surface and providing strong adhesion, thus improving the overall performance and durability in humid conditions.
Implementation Method 1
growing carbon nanotubes on both sides of an upper metal plate and a lower metal plate, respectively
Implementation Method 2
the composite material layers between the upper and lower metal plates are integrally bonded before the polymer composite material is dried, thus minimizing contact resistance between the two metal plates
Implementation Method 3
forming composite material layers by coating a polymer composite material thereon
Data Source
AI summary
A separator for a fuel cell and a method for manufacturing the same comprise two sheets of metal plates integrally formed to minimize contact resistance between an upper metal plate and a lower metal plate. The method for manufacturing the separator includes steps of preparing an upper metal plate and a lower metal plate, each plate having opposing main sides, and applying a coating liquid containing a polymer composite material on both sides of the upper and lower metal plates, to form first and second composite material layers on both sides of the upper plates and third and fourth composite material layers on both sides of the lower plates. The method further includes stacking the upper metal plate on the lower metal plate, before drying the respective composite material layers, and integrally bonding the second composite material layer and the third composite material layer to form a single intermediate composite material layer.