Metallic Separator Coating for Fuel Cells

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Solution Overview

Problem

Existing metallic separators for solid polymer electrolyte fuel cells face issues with corrosion resistance and conductivity, particularly when subjected to processing, such as peeling of noble metal layers and inadequate adhesion between layers, leading to decreased conductivity and mechanical strength.

Innovation Solution

A metallic material with a base metal coated by a metal compound layer containing transition metals and oxygen, with a platinum group portion dispersed on the surface and covered by a platinum group compound coating film, enhancing corrosion resistance and conductivity while maintaining adhesion during processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a noble metal layer is applied to improve corrosion resistance and conductivity, then corrosion resistance and conductivity are improved, but the noble metal layer peels during processing

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidadhesion stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies a composite coating structure consisting of a base metal layer, an intermediate metal compound layer containing transition metals and oxygen, and a platinum group compound coating film. This multi-layer composite structure improves adhesion between layers while maintaining corrosion resistance and conductivity, preventing peeling during processing.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces a metal compound layer containing transition metals and oxygen as an intermediate layer between the base metal and the platinum group compound coating film. This intermediate layer acts as a mediator that enhances adhesion between the base metal and the coating film, preventing peeling during processing while maintaining the protective and conductive properties.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a noble metal layer is applied to improve conductivity, then conductivity is improved, but contact resistance increases after processing

Engineering Contradiction:

ImproveconductivityVSAvoidcontact resistance control

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses a composite coating structure with a platinum group compound coating film on a metal compound layer. This composite structure maintains low contact resistance after processing by preventing peeling and ensuring good adhesion, while preserving the high conductivity provided by the platinum group elements.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If a thick metal compound layer is applied to improve adhesion, then adhesion is improved, but manufacturing complexity increases

Engineering Contradiction:

ImproveadhesionVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent optimizes the thickness of the metal compound layer to a specific range (5 nm to 50 nm) to achieve sufficient adhesion while controlling manufacturing complexity. By precisely controlling the thickness parameter, the patent balances adhesion improvement with manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

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 metallic material achieves excellent corrosion resistance and conductivity, even after processing, by improving adhesion and preventing peeling of the platinum group portion, thus maintaining low contact resistance and mechanical integrity.

Implementation Method 1

a metal compound layer which is stacked on a surface of the base metal and mainly contains a compound of at least one transition metal in the fourth period and oxygen

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

a platinum group compound coating film which covers the platinum group portion and mainly contains a compound of at least one platinum group element and oxygen

Methodology Applied

Scientific EffectCoating/Deposition: Deposition (physical)

Implementation Method 3

maintaining low contact resistance and mechanical integrity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10230115B2Metallic material, and conductive component including the same

Publication Date: 2019.03.12 NIPPON STEEL CORPORATION

AI summary

Provided is a metallic material including: a base metal made of a metal; a metal compound layer stacked on a surface of the base metal, the metal compound layer mainly containing a compound of at least one transition metal in the fourth period and oxygen; a platinum group portion dispersed on a surface of the metal compound layer, the platinum group portion mainly containing at least one platinum group element; and a platinum group compound coating film which covers the platinum group portion, the platinum group compound coating film mainly containing a compound of at least one platinum group element and oxygen. The at least one platinum group element contained in the platinum group portion is preferably one or more of Ru, Rh, Os, and Ir.