Fuel Cell Separator with Ti-O Intermediate Layer
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Solution Overview
Problem
Conventional fuel cell separator materials face challenges with adhesion, corrosion resistance, and durability, particularly in direct methanol fuel cells, due to issues with oxide layers and intermediate layers used in existing technologies.
Innovation Solution
A fuel cell separator material is developed with an intermediate layer containing Ti and O, and an alloy or Au single layer formed on a Ti base, providing strong adhesion and corrosion resistance through a specific composition and thickness gradient of Au, ensuring electrical conductivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an oxide layer is removed from the Ti base surface to improve Au layer adhesion, then adhesion property improves, but the Ti base becomes more susceptible to corrosion
Solution Approach 1:
An intermediate layer is formed on the Ti base surface before depositing the Au layer. This intermediate layer serves as a protective barrier that prevents direct contact between the Au layer and the Ti base, thereby maintaining corrosion resistance while providing a suitable surface for Au adhesion.
Solution Approach 2:
The intermediate layer acts as a mediator between the Ti base and the Au layer. It contains Ti and O in specific proportions (Ti: 1-50 at%, O: 50-99 at%) to create a surface that both adheres well to Au and protects the underlying Ti base from corrosive environments.
2Strength
If an intermediate layer is added between the Ti base and Au layer to improve adhesion, then adhesion property improves, but the structure becomes more complex
Solution Approach 1:
The intermediate layer is designed with specific local composition characteristics - containing Ti and O in controlled proportions - to provide the necessary adhesion properties locally at the Ti base interface, while the Au layer maintains its inherent corrosion resistance and conductivity properties in its own region.
3Reliability
If a thick Au layer is formed to ensure sufficient electrical conductivity and corrosion resistance, then electrical conductivity and corrosion resistance improve, but material cost increases
Solution Approach 1:
The intermediate layer is formed in advance on the Ti base surface, creating a protective and adhesive substrate that allows a thinner Au layer to achieve the same level of corrosion resistance and electrical conductivity that would otherwise require a much thicker Au coating on bare Ti.
Solution Approach 2:
The fuel cell separator uses a composite structure combining Ti base material with an intermediate layer of specific composition and a thin Au layer. This composite approach leverages the strengths of each material - Ti's mechanical properties, the intermediate layer's adhesion and protection, and Au's conductivity and corrosion resistance - to achieve overall performance with reduced Au content.
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 enables a fuel cell separator with improved corrosion resistance, electrical conductivity, and durability, suitable for direct methanol fuel cells, by forming a uniform Au layer on a Ti base with a gradient composition that enhances adhesion and resistance to corrosive environments.
Implementation Method 1
The intermediate layer is said to have good adhesion property with a base oxide layer, i.e., good binding property with O (oxygen atoms) and have good adhesion and binding properties with an Au layer
Implementation Method 2
The separator is also referred to as an interconnector, a bipolar plate or a current collector... The fuel cell separator has electrical conductivity, connects each single cell electrically
Data Source
AI summary
A fuel cell separator material, comprising an alloy layer 6 containing Au and a first component containing Al, Cr, Fe, Co, Ni, Cu, Mo, Sn or Bi, or an Au single layer 8 formed on a Ti base 2; an intermediate layer 2a containing Ti, O, the first component, and less than 20 mass % of Au arranged between the alloy layer or the Au single layer and the Ti base; wherein the alloy layer or the Au single layer has a region having a thickness of 1 nm or more from the uppermost to the lower layer and containing 50 mass % or more of Au, or a region having a thickness of 3 nm or more from the uppermost to the lower layer and containing Au in the range from 10-50 mass %, or the thickness of the Au single layer is 1 nm or more.