Corrosion Resistant Gas Diffusion Layer with Micro Protective Coating
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Solution Overview
Problem
Conventional carbon-based gas diffusion layers in fuel cells corrode when exposed to active oxygen species, while metallic layers offer better corrosion resistance but are costly and heavy, necessitating separate devices for fuel cells and water electrolysis cells, leading to increased space and expense.
Innovation Solution
A micro protective layer composed of corrosion-resistant metallic powders and highly active catalysts is coated onto the carbon-based gas diffusion layer to convert active oxygen species into non-active oxygen, preventing oxidation and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If carbon-based gas diffusion layer is used, then cost and weight are reduced, but corrosion resistance deteriorates due to oxidation by active oxygen species
Solution Approach 1:
The patent applies composite materials by combining carbon-based gas diffusion layer with a protective coating layer containing corrosion-resistant materials (such as Pt, Ir, Ru, or their oxides). This composite structure maintains the lightweight advantage of carbon materials while adding corrosion protection through the coating layer, directly resolving the contradiction between weight reduction and corrosion resistance improvement.
2Reliability
If metallic gas diffusion layer is used, then corrosion resistance is improved, but cost and weight increase
Solution Approach 1:
The patent applies local quality by providing corrosion protection only where needed - on the surface of the carbon-based gas diffusion layer that contacts active oxygen species. The protective coating is applied locally to the diffusion layer surface rather than using entirely metallic construction, achieving corrosion resistance while maintaining the overall lightweight carbon structure.
3Reliability
If separate devices are used for fuel cell and water electrolysis cell, then material compatibility is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent applies universality by designing a gas diffusion layer with protective coating that can function in both fuel cell mode and water electrolysis cell mode. The protective coating enables the same carbon-based diffusion layer to withstand active oxygen species in both oxidative (fuel cell) and reductive (electrolysis) environments, allowing one device structure to serve multiple functions and eliminating the need for separate devices.
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 solution allows for dual functionality in both fuel cells and water electrolysis cells without separate devices, reducing costs and preventing corrosion, enabling efficient energy conversion while maintaining structural integrity.
Implementation Method 1
a micro protective layer composed of corrosion-resistant metallic powders and highly active catalysts is coated onto the carbon-based gas diffusion layer to convert active oxygen species into non-active oxygen
Data Source
AI summary
A gas diffusion layer with a micro protective layer is utilized in the electrochemical cells. The cell mainly includes end plates, current collectors, flow field plates, gas diffusion layers, catalyst layers, a proton exchange membrane and a circuit unit. When the cell functions as a fuel cell, hydrogen reacts with oxygen to generate electricity and water. Reversely, when the cell functions as a water electrolysis cell, water was decomposed electrolytically to produce hydrogen and oxygen gases. In this manner, the present invention particularly has the gas diffusion layer to be coated with a micro protective layer so as to prevent the gas diffusion layer from being corroded by active oxygen species generated within the oxygen electrode under the catalysis during water electrolysis operation.