Fuel Cell Separator Conductive Oxide Film Mist CVD
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Solution Overview
Problem
Existing methods for manufacturing fuel cell separators with metal substrates face challenges in achieving both low manufacturing costs and sufficient conductive properties, as they require additional raw materials and processing steps, and existing mist CVD methods do not provide adequate conductive properties.
Innovation Solution
A method involving the formation of a conductive oxide film on a metal substrate using a mist CVD process with a raw material solution containing a precursor and hydrochloric acid, which atomizes to form a mist that reacts with the substrate to create a conductive oxide film while removing surface oxide films, thereby enhancing conductivity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metallic middle layer is introduced between the metal substrate and the conductive resin layer to suppress oxide film generation, then the conductive property is improved, but the manufacturing cost and manufacturing time increase due to additional raw materials and processing steps
Solution Approach 1:
The invention extracts and eliminates the unnecessary metallic middle layer from the separator structure. By using a conductive resin layer that directly contacts the metal substrate, the patent removes the intermediate layer while maintaining sufficient conductive properties, thereby simplifying the manufacturing process and reducing costs.
Solution Approach 2:
The invention replaces the expensive metallic middle layer with a cost-effective conductive resin layer. The conductive resin layer serves the same functional purpose of providing electrical conductivity and suppressing oxide formation, but at lower material and processing costs.
2Ease of manufacture
If the mist CVD method is used to form a conductive oxide film on the metal substrate, then the manufacturing process is simplified, but the conductive property is not sufficiently excellent
Solution Approach 1:
The invention uses a composite structure consisting of a metal substrate and a conductive resin layer. The conductive resin layer is formulated with specific components including a conductive polymer, a crosslinking agent, and a curing catalyst, creating a composite material that achieves both ease of manufacture and excellent conductive properties.
Solution Approach 2:
The invention optimizes the composition parameters of the conductive resin layer, specifically the ratios of conductive polymer to crosslinking agent and the addition of curing catalysts. These parameter changes enable the resin layer to achieve sufficient electrical conductivity while maintaining simplicity in the manufacturing process.
3Reliability
If a conductive resin layer is electrodeposited to coat the metal substrate, then the conductive property is improved, but additional raw material costs and processing steps are required
Solution Approach 1:
The invention merges the functions of corrosion protection, oxide film suppression, and electrical conductivity into a single conductive resin layer. This eliminates the need for separate metallic middle layers and multiple processing steps, thereby improving manufacturing efficiency while maintaining excellent conductive properties.
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 simplifies the manufacturing process while achieving significantly improved conductive properties and corrosion resistance for fuel cell separators, reducing costs and time, and ensuring effective electricity collection and cell connection.
Implementation Method 1
atomizing the raw material solution to generate a mist
Implementation Method 2
supplying the mist to the surface of the metal substrate to form the conductive oxide film on the surface of the metal substrate through a reaction by heat
Implementation Method 3
preparing a raw material solution containing a precursor of the conductive oxide film and hydrochloric acid
Data Source
AI summary
The present disclosure provides a method for manufacturing a fuel cell separator that ensures easy manufacture of the fuel cell separator having sufficiently excellent conductive property. The method for manufacturing the fuel cell separator according to the present disclosure is a method for manufacturing a fuel cell separator where a conductive oxide film is formed on a surface of a metal substrate using a mist CVD method, and the method includes: preparing a raw material solution containing a precursor of the conductive oxide film and hydrochloric acid; atomizing the raw material solution to generate a mist; and supplying the mist to the surface of the metal substrate to form the conductive oxide film on the surface of the metal substrate through a reaction by heat.