Graphite Resin Fuel Cell Separator With Aramid Fiber Reinforcement
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Solution Overview
Problem
Current separators for fuel cells, particularly in the carbon material group, face challenges in achieving high strength, low electrical resistance, and ease of thinning, which are essential for advanced battery technologies like lithium batteries and capacitors.
Innovation Solution
A separator comprising a plate made of graphite, thermoplastic resin, and aramid fiber, with a meta-phenylene group, and a barrier layer for improved gas barrier properties, is developed. The separator is produced using a method that involves shaping a mixture of graphite, resin, and aramid fiber in a mold with uneven surfaces to form grooves and apply barrier layers on both sides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If graphite particles are dispersed in thermoplastic resin to improve mechanical strength, then strength is improved, but electrical conductivity is insufficient and the separator cannot be made thinner
Solution Approach 1:
The patent uses a composite material consisting of graphite particles dispersed in thermoplastic resin. The graphite provides electrical conductivity while the resin provides mechanical strength. This composite structure allows the separator to achieve both high strength and high electrical conductivity simultaneously, resolving the contradiction between mechanical strength and electrical conductivity.
2Reliability
If carbon material separators are used to reduce specific gravity and improve corrosion resistance, then corrosion resistance is improved, but mechanical strength and processability deteriorate
Solution Approach 1:
The patent employs a composite material where carbon particles (graphite) are dispersed in a thermoplastic resin matrix. The carbon particles provide corrosion resistance and electrical conductivity, while the thermoplastic resin provides mechanical strength and processability. This composite approach allows the separator to achieve high corrosion resistance without sacrificing mechanical strength or processability.
3Strength
If metal separators are used to achieve high strength and thinness, then mechanical strength is improved, but specific gravity increases and corrosion resistance deteriorates
Solution Approach 1:
The patent uses a composite material of graphite particles in thermoplastic resin, which has a lower specific gravity than metal separators. The graphite provides strength and electrical conductivity, while the resin keeps the overall density low. This composite structure achieves high mechanical strength with low specific gravity, avoiding the weight penalty of metal separators.
4Reliability
If metal separators are coated with precious metal plating to improve corrosion resistance, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses a carbon-based composite material that inherently provides corrosion resistance without requiring expensive precious metal coatings. The graphite-resin composite is cost-effective and provides sufficient corrosion resistance for the application, eliminating the need for costly plating processes while maintaining reliability.
Data Source
AI summary
Provided are a separator having excellent strength and electrical conductivity and a method for producing the same. The present invention is related to a separator for a fuel cell or fuel cells comprising a plate containing graphite, resin, and aramid fiber different from the resin and to a method for producing the same. The plate comprises, on surfaces thereof, grooves serving as flow paths. The aramid fiber is para-aramid fiber containing a meta-phenylene group.