Fuel Cell Metal Separator Surface Layer for Corrosion and Conductivity
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Solution Overview
Problem
Existing metal separators in fuel cells face issues with corrosion resistance and electrical conductivity, particularly in the manifold parts, leading to potential corrosion and inadequate performance.
Innovation Solution
A metal separator design with a first and second manifold part, each having a plurality of openings and a surface-modified layer, formed on the upper surface and inner surfaces of the openings, using a specific composition and heat treatment process to enhance corrosion resistance and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface modification is performed before manifold part piercing, then corrosion resistance is improved, but exposed parts occur in manifold parts and corrosion resistance is not ensured
Solution Approach 1:
The patent applies preliminary action by forming the surface layer on the metal separator base material before performing the manifold part piercing process. This ensures that the surface layer is already present to protect against corrosion before any exposing occurs during piercing. The surface layer is then restored or reinforced after piercing to maintain corrosion resistance throughout the manifold parts.
2Ease of operation
If manifold part piercing is performed, then hydrogen and air supply functions are achieved, but surface layer is exposed and corrosion resistance deteriorates
Solution Approach 1:
The patent applies local quality by selectively restoring or reinforcing the surface layer specifically in the manifold parts where openings are formed, rather than treating the entire separator uniformly. This ensures that the critical manifold regions have enhanced corrosion resistance while maintaining the gas supply function through the openings.
3Reliability
If chromium content is increased, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by optimizing the chromium content to a specific range (23-30 wt%) rather than simply increasing it indefinitely. This optimized range provides sufficient corrosion resistance while controlling manufacturing costs. Additionally, the surface layer formation process enhances corrosion resistance through controlled oxidation rather than relying solely on high chromium 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 provides a metal separator with improved electrical conductivity and corrosion resistance, ensuring stable operation of fuel cells by preventing corrosion and maintaining efficient electrochemical reactions.
Implementation Method 1
a surface-modified layer is formed on an upper surface of surface layer parts and an inner surface of the openings
Data Source
Figure 1~2
Figure 3
AI summary
The present application relates to a metal separator and a manufacturing method therefor, the metal separator comprising a first base material comprising a first manifold part, a second manifold part, and a reaction part provided between the first and second manifold parts, wherein the first and second manifold parts each have a plurality of openings and surface portions present between the plurality of openings, and the upper surfaces of the surface portions and the inner surfaces of the openings each have a surface-modified layer. According to the metal separator and the manufacturing method therefor, not only electrical conductivity but also corrosion resistance can be excellent.